ST 330-87-1987 Chevrolet Light Duty Truck Service Manual

SEC
NAME
GENERAL INFORMATION
0A
OB
1987
HEATING AND AIR CONDITIONING

1A
1B
LIGHT DUTY
TRUCK
SERVICE
MANUAL
Front End Alignment

Steering Linkage
Manual Steering
Power Steering
Steering Column
Front Suspension and Axle
Rear Suspension
Wheels and Tires
PROPELLER SHAFT AND AXLES

4A Propeller Shaft
4B Rear Axle
4C Front Driving Axle
BRAKES
ENGINE
6A
6A3
6A4
6A5
6A6
6A7
6B1
6B2
6C
6C1
6C2
6D
6E
6E8
6E9
6F
6H
R-V, P-TRUCK
AND G-VAN
MODELS
The Table of C ontents on th is page in
d icates the sections covered in th is m an
ual. At the begin nin g of each individual
section is a Table of C ontents w hich gives
the page n um be r on w hich each m ajor
su bject begins.
Engine
4.3 Liter V6
Small Block
7.4 Liter V8
6.2 Liter Diesel
4.8 Liter L6
Engine Cooling
Radiator
Fuel System
Carburetors
Diesel Fuel Injection
Engine Electrical
Drivability And Emissions
Drivability And Emissions - Carburetor
Drivability And Emissions - Diesel
Exhaust
Vacuum Pump
TRANSMISSION AND CLUTCH

7A
7B
7C
7D1
7D2
W hen reference is m ade in th is m anual

to a brand name, number, or sp e cific tool,
an e qu iva len t product m ay be used in
place of the recom m ended item.
Automatic Transmission
Manual Transmission
Clutch
205 Transfer Case
208 Transfer Case
ELECTRICAL
8A Cab Electrical
8B Chassis Electrical
8C Intrument Panel
All inform ation, illustrations, and sp eci

fica tion s contained in th is M anual are
based on th e latest p roduct inform ation
available at th e tim e of p ub lica tion ap
proval. T he rig h t is reserved to m ake
changes at any tim e w itho ut notice.
P rinted in U.S.A.
1986 G eneral M otors C orporation
Frame and Bumpers

Sheet Metal
STEERING, SUSPENSION, WHEELS AND TIRES

3A
3B1
3B2
3B3
3B4
3C
3D
3E
Heating
Air Conditioning
FRAME AND CAB

2A
2B
General Information
Maintenance and Lubrication
ACCESSORIES
10
BODY
10A1
10A2
10A3
10A4
10A5
INDEX
July, 1986
iii
Doors
Seats
Glass
Interior Trim
Endgate
He knows
quality parts
make a difference
even on
simplejobs.
Mr. Goodwrench wants you to have the right parts for
your truckwhether you see him for service or whether
you do the work yourself.
So keep that great GM feeling with genuine GM parts

at participating independent Mr. Goodwrench dealers
selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,
Cadillacs, GMC and Chevy Trucks.
Thats why Mr. Goodwrench wants to have a good

stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and
transmissions to GM Goodwrench Motor Oil that meets
or exceeds all specifications for General Motors cars
or light trucks. And Mr. Goodwrench has a complete
line of GM chemicals for fine care of your GM vehicle.
Plus accessories to add convenience
or just a little extra style.
O iN E R A l MOTORS CORPORATION
)VA(joodxtrijM C^
B-05884
iv
FOREWORD
This service manual contains diagnosis, On-Vehicle maintenance, and light repair for
Light Duty Truck Models ( R-V, P-Truck, and G-Van ). Fuel and emissions related compo
nents for throttle body injection vehicles are covered in a separate manual. Procedures
involving disassem bly and assembly of major components for these vehicles are published
in a separate Truck Unit Repair M anual. W iring diagrams for these models are also
published in a separate Truck W iring Diagram booklet.
This manual should be kept in a handy place for ready reference. If properly used, it will
meet the needs of technicians and vehicle owners.
L *-/ - vp 'sEtyg. Ho Ipl
CAUTION:
These vehicles contain some parts dim ensioned in the metric system as well as in the
customary system. Some fasteners are metric and are very close in dimension to fam iliar
custom ary fasteners in the inch system. It is important to note that, during any vehicle
maintenance procedures, replacement fasteners must have the same measurements and
strength as those removed, whether metric or customary. (Numbers on the heads of metric
bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial
lines for this purpose, while most custom ary nuts do not have strength markings.) Mis
matched or incorrect fasteners can result in vehicle damage or malfunction, or possibly
personal injury. Therefore, fasteners removed from the vehicle should be saved for re-use
in the same location whenever possible. Where the fasteners are not satisfactory for re
use, care should be taken to select a replacement that m atches the original. For informa
tion and assistance, see your authorized dealer.
CHEVROLET MOTOR DIVISION

General Motors Corporation
Detroit, Michigan
CAUTION
To reduce the chance of personal injury and/or property damage, the fo l
lowing instructions must be carefully observed.
Proper service and repair are important to the safety of the service techni
cian and the safe, reliable operation of all motor vehicles. If part replacement
is necessary, the part must be replaced with one of the same part number or
with an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended and described in this service man
ual are effective methods of performing service and repair. Some of these
procedures require the use of tools specially designed for the purpose.
Accordingly, anyone who intends to use a replacement part, service pro
cedure or tool, which is not recommended by the vehicle manufacturer,
must first determine that neither his safety nor the safe operation of the
vehicle will be jeopardized by the replacement part, service procedure or
tool selected.
It is important to note that this manual contains various Cautions and No
tices that must be carefully observed in order to reduce the risk of personal
injury during service or repair, or the possibility that improper service or
repair may damage the vehicle or render it unsafe. It is also important to
understand that these Cautions and Notices are not exhaustive, because
it is impossible to warn of all the possible hazardous consequences that
might result from failure to follow these instructions.
O A -1
SECTION 0
GENERAL INFORMATION
CONTENTS
SUBJECT
PAGE
G eneral In fo r m a t io n ........... ................................................................................................................ ....................................0A - 1

M aintenance and L u b ric a tio n ............................................................. ............................................... ................................... ,0 8 - 1
SECTION 0A
GENERAL INFORMATION
CONTENTS
SUBJECT
PAGE
S e rvice Parts Id e n tific a tio n L a b e l ........................................................................................................................ ............0 A - 1

V e hicle Id e n tific a tio n P la te .................................................. ............................................... ............................... ...QA- 1
C e rtific a tio n L a b e l.................................................................. ..................................... ........................ ............................... .0 A - 2
Model R e fe r e n c e ....................................... ................................................................................. ............................................. 0 A - 2
Engine id e n tific a tio n N u m b e r........................................... ........................................ ........................ ................................. 0 A - 2
V ehicle L iftin g P ro c e d u re s ........................................... ............................................................................... ........................ 0 A - 3
E m ergency S ta rtin g Due to a D ischarged B a tte r y ................................................................................................ ..
,0 A - 8
G raphic S y m b o ls .................................................................................................................................................................... .0 A - 8
M etric F a s te n e r s .......................................................................................................................................................................... 0A-1Q
Fastener S tre n g th Id e n tific a tio n ............................................................................................. ...........................................0 A -1 0
P re vailin g T orq ue F a s te n e rs ..................................................... .......................................... ............................................... 0A -11
S ix Lobed S o cke t Head F a s te n e rs ............................................................. ............................ ...................... ....................O A -12
RPO L is tin g (R egular P ro d u ctio n O p tio n ).................................................................... .......................................... ...0 A -15
SERVICE PARTS
IDENTIFICATION LABEL
The Truck Service Parts Identification Labei is provided
on all models (figure 1). It is located on the inside of the
gloye box door (or on an inner body panel for Forward
C o n tro l m odels). The L ab el lists th e V iN (V e h ic le
Identification Number), wheelbase, paint information and
all Production options or Special Equipm ent on the
vehicle when it was shipped from the factory. ALWAYS
REFER TO THIS INFORMATION WHEN ORDERING
PARTS.
VEHICLE IDENTIFICATION
NUMBER
The VIN is the legal identifier of the vehicle, On all
models except Forward Controi, it is located on a plate
which is attached to the left top of the instrum ent panel
and can be seen through the windshield from the outside
of the vehicle (figure 2). On Forward Control models, the
plate is on the dash and toe panel. To find out the
15516776
P rinte d in U.S.A
SERVICE
PARTS
IDENTIFICATION
THE O P TIO N A L EQ UIPM EN T LISTED 3E LO W H AS BEEN

V E H IC L E FOR PROPER ID E N T IF IC A T IO N OF R E P L A C E M E N T
$URE TO SPEC IFY THE A P PLIC ABLE OPTION NU M BER S.
PARTS.
NOTICE: TH IS IN F O R M A T IO N IS SUPPLIED AS AN AID IN '.DENTIFYING PARTS FOR SERVICE.

SERVICE PARTS R EQ U IR EM EN TS FOR TH IS VE H IC LE M AY VARY FROM TH O SE LISTED.
BEFORE O R D ER IN G ANY OF THE A B O VE PARTS, A LW A YS HAVE YOUR GE NE RA L
M OTORS TRUCK DEALER CH EC K THIS V E H IC L E 'S BR OADC AST SU PP LE M E NT FOR
PO SSIBLE PART C H AN G ES .
IM PO RTAN T: RETAIN TH IS PLATE A S A
PERM ANE
* 8-05559
F igure 1 S e rvice Parts Id e n tific a tio n Label

manufacturer, model and chasis type, engine type, GVW
range, model year, plant code, and sequential number,
refer to figure 3.
OA-2 GENERAL INFORMATION
1GCDC14N4GF100001
o
1. T ypica l VIN
F-00687
Figure 2VIN Location
GVWR. Also, the front and rear gross axle weights must
not exceed the front and rear GAWRs.
The Payload Rating shown on the label is the maximum
allowable cargo load (including the weight of the driver
and all occupants) that the vehicle can carry based on all
factory installed equipm ent on the vehicle. The Payload
Rating is reduced if any accessories or other equipm ent
is added to the vehicle after final date of manufacture.
The weight of these items should be determined and
deducted from the Payload Rating.
T h e v e h ic le m ay a ls o h a ve a G C W R (G ro s s
C o m b in a tio n W e ig h t R a tin g ). T h e G C W (G ro s s
Com bination Weight) is the total weight of the loaded tow
vehicle (including passengers) and a loaded trailer.
The tires on the vehicle must be the proper size and
properly inflated for the load which you are carrying. The
vehicle Certification Label shows the originally equipped
tire size and recommended inflation pressures. For more
inform ation on tires, refer to W HEELS AND TIRES
(Sec.3E).
MODEL REFERENCE
CERTIFICATION LABEL
The Certification Label shows the GVWR, and the front
and rear GAWRs, and the Payload Rating for your vehicle
(figure 4).
Refer to figures 5 and 6 to determine the vehicle

model. For R/V models, a R is a two-wheel drive vehicle
and a V is a four-wheel drive vehicle.
Gross Vehicle W eight (GVW) is the w eight of the

orginally equipped vehicle and all items added to it after it
has left the factory. This would include bodies, winches,
booms, etc.; the driver and all occupants; and the load the
ve hicle is carrying. The GVW m ust not exceed the
Nation of Origin
ENGINE IDENTIFICATION
NUMBER
Refer to figure 7 to determine the location of the engine
I.D. number.
Ti
Code Series
1
V2 Ton
1 = U.S. B u ilt
2 = C a nadian B u ilt
3 = M e xican B u ilt
Jon
A
B
C h evro let Bus *

C h evro let In c o m p le te
C h evro let Truck
D
G M C In c o m p le te
E
C a d illa c In c o m p le te
H
GM o f C anada Bus
T
G M C Truck
IGJ G M C Van/Bus
IGK G M C MPV
IGN C h evro let MPV
*Van w ith 4th Seat
Code
GVWR/BRAKE SYSTEM
GVWR Range Brake System
B
3001-4000
C
4001-5000
D
5001-6000
E
6001-7000
F
7001-8000
G*
8001-9000
H
9001-10,000
J
10,001-14,000
K
14,001-16,000
' In c lu d e s G-Van Bus
Code
H
Code Body Type
Code Make
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
H y d ra u lic
1 Ton
Manufacturers
G = G eneral M o to rs
Production Sequence Number
0
1
2
3
4
5
6
7
8
9
Assembly Plant
Year
1987
B a ltim ore , MD
F lin t, M l
Ja n e s v ille , W l
St. Lou is, MO
P o n tia c East, M l
P ontiac, Ml
F ort W ayne, IN
O shaw a, ON
M oraine, OH
D e tro it, M l
S c a rb o ro u g h , ON
L o rd s to w n , OH
S h re ve p o rt, LA
Pontiac, Ml______
P ickup/P ane l D e livery

H i-C ube/C u taw ay Van
Forw ard C o n tro l
Fou r-D oo r Cab
Tw o-D oor Cab
Van
S u burban
M o to r H o m e C h a s s is
U tility (Jim m y/B lazer)
S take
Code
Line and Chassis Type

Chassis
Type
Line
R C o n v e n tio n a l Cab
D M ilita ry Truck
V C o n v e n tio n a l Cab
G Van
P Forw ard C o n tro l
S Sm Conventional Cab
T Sm Conventional Cab
M Sm Van
4
4
4
4
4
4
4
4
x
x
x
x
x
x
x
x
2
4
4
2
2
2
4
2
Code
C
E
H
J
K
N
R
Z
M
W
Engine Type and Make

Type
Producer
DDAD
P o ntiac
C h evro let
DDAD
C h evro let
Chevrolet
C h e v ro le t
Chevrolet
Chevrolet
Chevrolet
6.2L
2.5L
5.0L
6.2L
5.7L
7.4L
2.8L
4.3L
5.7L
7.4L
V8 D iesel
L4 TBI
V8 TBI
V8 Diesel
V8 TBI
V8 TBI
V6 TBI
V6 TBI
V8 4BBL
V8 4BBL
RPO
LH6
LN 8
L03
LL4
LOS
L19
LL2
LB4
LT9
LE8
F-02139
Figure 3Vehicle Identification Number (VIN)
GENERAL INFORMATION OA-3

When lifting the R vehicle with a hoist, the rear hoist
pads should be positioned under the rear spring front
hangers.
' MFD. BY GENERAL MOTORS CORPORATION

GVW R
g AWR
PRT
gaw r rr
When lifting the V vehicle with a hoist, the front hoist

pads should be positioned under the frame, at the front
body mount. The rear hoist pads should be positioned
under the rear spring front hangers.
SEE O W NER'S MANUAL FOR ADDITIONAL INFORMATION
When lifting the front of the V vehicle with a floor jack,

position the jack pad at the center of the axle, not under
the front differential.
F-01407
When lifting the P vehicle with a hoist, the rear hoist
pads should be positioned under the fram e and inboard of
the rear spring front hangers.
Figure 4Certification Label
VEHICLE LIFTING PROCEDURES

F or liftin g a v e h ic le , v a rio u s lif t p o in ts
recommended. Refer to figures 8, 9, 10, and 11.
P icku p , R e g u la r C ab
a re
When lifting the G vehicle with a hoist, the rear hoist

pads should be positioned under the rear spring forward
hangers.
R V MODELS
C h a s s is - Cab, R e g u la r C ab
C h a s s is - Cab, B o n u s /C re w C ab
P ic k u p , B o n u s/C re w C ab
S u b u rb a n
U tility V e h ic le
J im m y (Blazer)
F-02281
Figure 5RV Models
G VAN MODELS
V A N D U R A (C H E V Y VAN )
B A LL Y (SPO R TV AN )
CUTAWAY VAN
MAGNAVAN (HI-CUBE VAN)
MODELS___________
VALUE VAN (STEP VAN)
(ALUMINUM)
VALUE VAN (STEP VAN)

(STEEL)
MOTOR HOME CHASSIS
FORWARD CONTROL CHASSIS
B-09178
Figure 6G Van and P Models
Figure 7Engine I.D. Number Location
A.
B.
C.
D.
E.
F.
L ow er c o n tro l arm ; in b o a rd o f th e lo w e r ball jo in t.

F ro n t s u s p e n s io n c ro s s m e m b e r; center.
F ram e at to w a rd b o d y m o u n t.
R ear s p rin g fo rw a rd hanger.
R ear axle; b e tw e e n th e s p rin g and brake b a c k in g p la te
D iffe re n tia l case; center.
V e h ic le J a c k o r F lo o r J a c k
F lo o r J a c k
H o is t
B-07500
Figure 8Chassis Lift Points R Model
A.
B.
C.
D.
E.
F.
G.
F ro n t axle; c lo s e to w h e e l as p o s s ib le .
F ro n t axle; at s ta b iliz e r b a r m o u n t.
F ro n t axle; at center.
Fram e; at fro n t b o d y m o u n t.
R ear s p rin g at fro n t m o u n t.
R ear a xle; at s p rin g m o u n t.
R ear axle, at c e n te r o f d iffe re n tia l.
V e h ic le J a c k
o r F lo o r J a c k
/ \
V e h ic le J a c k
F lo o r J a c k
Two C o lu m n H o is t
Two C o lu m n H o is t
H o is t
B-07501
Figure 9Chassis Lift Points V Model
A.
B.
C.
D.
E.
F.
Low er c o n tro l arm ; in b o a rd o f th e lo w e r b all jo in t

F ro n t s u s p e n s io n c ro s s m e m b e r; center.
Fram e; at in w a rd bend.
Rear s p rin g ; at fo rw a rd s p rin g hanger.
A xle ; at s p rin g m o u n t.
D iffe re n tia l; at center.
V e h ic le J a c k o r F lo o r J a c k
O F lo o r J a c k
f H H o is t
B-07627
Figure 10Chassis Lift Points G Model
A.
B.
C.
D.
E.
F ro n t axle; at th e s p rin g m o u n t.
Fram e; at th e cro s s m e m b e r, ju s t b e h in d th e s p rin g m o u n t
Fram e; at th e c ro ssm e m b e r.
Rear a xle; at th e s p rin g m o u n t.
R ear axle; at th e d iffe re n tia l.
F lo o r J a c k
B-07628
Figure 11Chassis Lift Points P Model

Any tim e a vehicl is lifted with a vehicle jack or a floor
jack, the wheels at the opposite end of the lifted end
should be chocked. Also, jack stands should be used to
provide support. When supporting the vehicle with jack
stands, the jack stands should be placed under the frame,
the front suspension crossm em ber or the axle.
When removing m ajor components of the vehicle while
the vehicle is on a hoist, the vehicle frame should be
chained to the hoist pads in order to prevent tip-off.
NOTICE: When jacking or lifting a vehicle, be
certain that the lift pads do not contact the
catalytic converter, brake lines, brake cables, or
fuel lines. Such contact may result in damage or
unsatisfactory vehicle performance.
EMERGENCY STARTING
YOUR VEHICLE DUE TO A
DISCHARGED BATTERY
If your vehicle will not start due to a discharged battery,
it can often be started by using energy from another
battery - a procedure called jum p starting.
Should your vehicle have an optional diesel engine with
two batteries:
P models and G Van models use only the battery on
the drivers side when jump starting.
R/V models use only the battery on the passengers
side when jump starting.
These battery locations are closer to the starter, thus
reducing electrical resistance. Ignore the second battery.
NOTICE: Do not push or tow this vehicle to start
it. Under some conditions this may damage the
catalytic converter or other parts of the vehicle.
Also, since this vehicle has a 12 volt battery, be
sure the vehicle or equipm ent used to jum p
start your engine is also 12 volt. Use of any
other type system may damage the vehicles
electrical components.
At low temperatures, it may not be possible to start your
diesel engine from a single battery in another vehicle.
However, you can use your vehicle to jum p start another
vehicle.
JUMP STARTING INSTRUCTIONS

CAUTION: Batteries produce explosive gases,
contain corrosive acid, and supply levels of
electrical current high enough to cause burns.
Therefore, to reduce the risk of personal injury
when working near a battery:
Always shield your eyes and avoid leaning
over the battery whenever possible.
Do not expose the battery to open flames
or sparks.
Be sure any batteries that have filler caps
are properly filled with fluid.
Do not allow battery acid to contact eyes
of skin. Flush any contacted area with
water immediately and throughly, and get
medical help.
Follow each step in the jump starting
instructions.
M ake C on ne ction s in N um erical O rder

First Jum per Cable
Do NOT Allow
Vehicles to Touch I
D ischarged
B a tte ry
Second Jum per Cable
Make Last
C onnection on
Engine or Frame,
Away from Battery
B a tte ry in V e hicle
w ith C harged B a tte ry I
F-02649
F igure 12J u m p S ta rtin g C on ne ction s
1. Position the vehicle with the good (charged) battery so
that the booster (jumper) cables will reach, but never
let the vehicles touch. Also, be sure booster cables do
not have loose or missing insulation.
2. In both vehicles:
Turn o ff th e ig n itio n and a ll lig h ts and
accessories except the hazard flasher or any
lights needed for the work area.
Apply the parking brake firmly, and shift the
autom atic transm ission to Park (or manual
transmission to Neutral).
3. Making sure the cable clamps do not touch any other
metal parts, clamp one end of the first booster cable to
the positive ( + ) terminal on one battery, and the other
end to the positive terminal on the other battery (figure
12). Never connect ( + ) to (-).
4. Clamp one end of the second cable to the negative (-)
terminal of the good (charged) battery and make the
final connection to a heavy metal bracket (such as the
mounting bracket for the generator or air conditioner
compressor if so equipped) on the engine about 450
millimeters (18 inches) from the discharged battery.
Make sure the cables are not on or near pulleys, fans,
or other parts that will move when the engine is
started.
5. Start the engine of the vehicle with the good (charged)
battery and run the engine at a moderate speed for
several minutes. Then, start the engine of the vehicle
that has the discharged battery.
6. Remove the booster cables by reversing the above
installation sequence exactly. While removing each
clamp, take care it does not touch any other metal
while the other end remains attached.
GRAPHIC SYMBOLS
G raphic sym bols are used on som e controls and
displays on the vehicle (figure 13). Many of these symbols
are used internationally.
ff t t
BRAKE
4>
POWER TRAIN
OIL TEMPERATURE
|0
ILLUM INA TION
CONTROL
FOG LAM P
V ENTILATING FAN
W IND SHIELD
DEFROSTER
REAR W IND O W
DEFOGGER
FASTEN
SEAT BELTS
FUEL
ENGINE OIL
PRESSURE
IDENTIFICATION
LAM PS
LIGHTS OR
HIGH BEAM
HORN
HAZARD W ARNING
FLASHER
TURN SIGNALS
>
CAUSTIC
BATTERY ACID
COULD CAUSE BURNS
BRAKE
SPEAKER
------------------------
LIGHTER
CHOKE
RADIO
SELECTOR
DOOR
LOCK/UNLOCK
BATTERY
CHARGING
SYSTEM
HEATER
st
RADIO VOLUME
SPARK OR FLAME
COULD
EXPLODE BATTERY
'I
PARKING LIGHTS
IIIUII
LJ------- 1
CAUTION
POSSIBLE INJURY
W IND SHIELD
WIPER
h e r
W IND SHIELD
W IPER & W ASHER
nm
ID
IPS
f
W IND SHIE LD
W ASHER
\\\W
HEADLIGHT
LOWER BEAM
kPa
MANIFOLD
V ACUUM
TRANSM ISSION
OIL TEMPERATURE
HOOD
RELEASE
F-02392
Figure 13Graphic Symbols
0A-10 GENERAL INFORMATION
METRIC FASTENERS
1.
2.
3.
4.
5.
6.
7.
G rade 2 (GM 200-M)

G rade 5 (GM 280-M)
G rade 7 (GM 290-M)
G rade 8 (G M 300-M)
M a n u fa c tu re rs Id e n tific a tio n
N u t S tre n g th Id e n tific a tio n
Id e n tific a tio n M a rks (P o sid riv S crew Head)
1.
2.
A.
B.
C.
D.
F-00695
C u s to m a ry B o lt 1/4-20
M e tric B o lt M6.0x1
1/4-inch
6 mm
20 T h re a d s Per In ch
1 T hre ad Per M illim e te r
(25.4 T h re a d s Per In ch)
F-00705
Figure 14Bolt and Nut Identification
Figure 15Thread Notation
Models are prim arily dim ensioned in the metric system.

Many fasteners are m etric and are very close in dim en
sion to well-known custom ary fasteners in the inch sys
tem. It is most important that replacement fasteners be of
the correct nominal diameter, thread pitch and strength.
the metric M6.0X1 screw which has nearly the same diam
eter and has 25.4 threads per inch. The thread pitch is in
between the custom ary coarse and fine thread pitches.
Original equipm ent metric fasteners (except beauty

bolts, such as exposed bum per bolts, and cross recess
head screws) are identified by a number marking indica
ting the strength of the material in the fastener as outlined
later. Metric cross recess screws are identified by a Posi
driv or Type 1A shown in figure 14. Either a Phillips head
or Type 1A cross recess screwdriver can be used in Posi
driv recess screw heads, but Type 1A cross recess screw
drivers will perform better.
FASTENER STRENGTH
IDENTIFICATION
NOTICE: Most m etric fasteners have a blue

color coating. However, this should not be used
as positive identification as some fasteners are
not color coated.
General Motors Engineering Standards, along with
other North American Industries, have adopted a portion
of the standard metric fastener sizes defined by ISO (In
ternational Standards Organization). This was done to re
duce the num ber of fastener sizes used and yet retain the
best strength qualities in each thread size. For example,
the customary 1/4-20 and 1M-28 screws are replaced by
Metric and customary thread notation differ slightly. The

difference is shown in figure 15.
Most comm only used metric fastener strength property

classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Custom ary (inch)
strength classes range from grade 2 to 8 with radial line
identification embossed on each bolt head. M arkings
correspond to two lines less than the actual grade (i.e.
grade 7 bolt will exhibit 5 embossed radial lines on the
bolt head). Some metric nuts will be marked with single
digit strength identification numbers on the nut face.
Figure 14 shows the different strength markings.
When replacing metric fasteners, be careful to use bolts
and nuts of the same strength or greater than the original
fasteners (the same num ber marking or higher). It is
likewise important to select replacement fasteners of the
correct size. Correct replacement bolts metric fasteners
available in the aftermarket parts channels were designed
to metric standards of countries other than the United
States, and may be of a lower strength, may not have the
num bered head m arking system , and may be of a
(I I)
A
6 & 6.3
10
12
14
16
20
N-m
0.4
0.8
1.4
2.2
3.0
4.2
7.0
In. Lbs.
4.0
7.0
12
18
25
35
57
1 ,2 , 3, 6,
N-m
0.4
0.6
1.2
1.6
2.4
3.4
5.6
7, 8, 9
In. Lbs.
4.0
5.0
10
14
20
28
46
.250
.312
.375
.437
.500
.562
.625
.750
Nm
0.4
0.6
1.4
1.8
2.4
3.2
4.2
6.2
In. Lbs.
4.0
5.0
12
15
20
27
35
51
1 ,2 , 3, 6,
N-m
0.4
0.6
1.0
1.4
1.8
2.6
3.4
5.2
8, 9
In. Lbs.
4.0
5.0
9.0
12
15
22
28
43
4 ,5
4 ,5
A. M e tric S ize s
B. In ch S izes
1.
2.
3.
4.
5.
T op L o c k T ype
C e n te r L o c k
D ry A d h e s iv e C o a tin g
O u t O f R ou nd T hre ad
D e fo rm e d T h re ad P ro file
6.
7.
8.
9.
N y lo n
N y lo n
N y lo n
N y lo n
S trip O r P atch
W a s h e r In s e rt
P atch
In s e rt
B-02406
Figure 16 T o rq u e N uts and B o lts C hart

different thread pitch. The metric fasteners used on GM
products are designed to new, international standards that
may not yet be manufactured by some non-domestic bolt
and n u t s u p p lie rs . In g e n e ra l, e x c e p t fo r s p e c ia l
applicaitons, the common sizes and pitches are:
M6.0 x 1
M 1 0 x 1 .5
M 8 x 1.25
M 12 x 1.75
PREVAILING TORQUE FASTENERS

A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accom plished by distortion of the top of an
all-metal nut by using a nylon patch on the threads in the
middle of the hex flat. A nylon insert may also be used as
a method of interference between nut and bolt threads
(figure 16).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads, or the threads
of a tapped hole. This is accomplished by distorting some
of the threads or by using a nylon patch or adhesive
(figure 12).
RECOMMENDATIONS FOR REUSE:

1. Clean, unrusted prevailing torque nuts and bolts may
be reused as follows:
a. Clean dirt and other foreign material off the nut
or bolt.
b. Inspect the nut or bolt to insure there are no
cracks, elongation, or other signs of abuse or
overtightening. (If there is any doubt, replace
with a new prevailing torque fastener or equal or
greater strength).
c. Assemble the parts and hand start the nut or
bolt.
d. Observe that, before fastener seats, it develops
torque per the chart in figure 10 (if there is any
doubt, replace with a new prevailing torque
fastener of equal or greater strength).
e. Tighten the fastener to the torque specified in the
appropriate section of this manual.
2. Bolts and nuts which are rusty or damaged should be
replaced with new parts or equal or greater strength.
T - In te rn a l D rive
E - E x te rn a l D rive
______________________________________________ B-02221
Figure 17Six Lobed Socket Head Fasteners
SIX LOBED SOCKET

HEAD FASTENERS
Six lobed socket head fasteners are used in some
applications on vehicles covered in this manual (figure
17). The door striker bolt is of this design.
Tools d esign ed fo r th ese fa ste ne rs are availab le
commercially. However, in some cases, if the correct tool
is not available, a hex socket head wrench may be used.
CONVERSION TABLE
M u ltip ly
by
to g e t e q u iv a le n t
n u m b e r o f:
M u ltip ly
LENGTH
Inch
Foot
Yard
Mile
25.4
0.304 8
0 .9 1 4 4
1.609
Figure
m illim eters2 (m m 2)
centim eters2 (cm 2)
m eters2 (m2)
meters2
VOLUME
Inch3
Table
Quart 0.946 4
Gallon
Yard3
16.387
16.387
0 .01 64
liters
3.785 4
0.764 6
mm3
cm 3
liters (I)
liters
m eters3(m 3)
Foot/sec2
Inch/sec2
0.453 6
907.18
0.907
Pound-inch
Pound-foot
9.807
0.278 0
4.448
kilogram s (kg)
kilograms (kg)
tonne (t)
newtons (N)
newtons
newtons
TEMPERATURE
Degree
Fahrenheit
CO
"si
new ton-m eters (N-m)

new ton-m eters
POWER
Horsepower
Inches of water
Pounds/sq. in.
0.746
kilow atts (kW)
PRESSURE OR STRESS
0.249 1
6 895
kilopascals (kPa)
kilopascals
ENERGY OR W ORK
BTU
Foot-pound
Kilowatt-hour
1 055
1.355 8
3 600 000
or 3.6 x 106
joules (J)
joules
joules (J $ one W)
Foot candle
1.076 4
lum ens/m eter2 (lm /m 2)
FUEL PERFORM ANCE

Miles/gal
Gal/mile
0.425 1
2.352 7
M iles/hour
1.609 3
kilom eters/liter (km/l)

liter/kilom eter (l/km)
VELO CITY
kilom eters/hr. (km/h)
(tF -3 2 ) -f- 1.8 degree C elsius (C)
OA-13
oo
0
01
0.112 98
1.355 8
LIG H T
FORCE
Kilogram
Ounce
Pound
m eter/sec2 (m /s2)
m eter/sec2
TORQUE
MASS
Pound
Ton
Ton
0.304 8
0.025 4
GENERAL INFORMATION
18 Conversion
Foot2
Yard2
645.2
6.45
0.092 9
0.836 1
to g e t e q u iv a le n t
n u m b e r o f:
AC C ELER ATIO N
m illim eters (mm)
meters (m)
meters
kilom eters (km)
AREA
Inch2
by
OA-14
DECIMAL AND METRIC EQUIVALENTS

Decimal In.
M etric mm
Fractions
Decimal In.
M etric mm
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.125
0.140625
0.15625
0.171875
0.1875
0.203125
0.21875
0.234375
0.250
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.375
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.500
0.39688
0.79375
1.19062
1.58750
1.98437
2.38125
2.77812
3.1750
3.57187
3.96875
4.36562
4.76250
5.15937
5.55625
5.95312
6.3500
6.74687
7.14375
7.54062
7.93750
8.33437
8.73125
9.12812
9.52500
9.92187
10.31875
10.71562
11.11250
11.50937
11.90625
12.30312
12.7000
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.625
0.640625
0.65625
0.671875
0.6875
0.703125
0.71875
0.734375
0.750
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.875
0.890625
0.90625
0.921875
0.9375
0.953125
0.96875
0.984375
1.00
13.09687
13.49375
13.89062
14.28750
14.68437
15.08125
15.47812
15.87500
16.27187
16.66875
17.06562
17.46250
17.85937
18.25625
18.65312
19.05000
19.44687
19.84375
20.24062
20.63750
21.03437
21.43125
21.82812
22.22500
22.62187
23.01875
23.41562
23.81250
24.20937
24.60625
25.00312
25.40000
GENERAL INFORMATION
Figure 19Decimal and Metric Equivalents
Fractions
RPO LISTING
(REGULAR PRODUCTION OPTION)
The RPO list contains RPOs used on R-V Models, G
Vans, and Forward Control Chassis Models. Refer to the
Service Parts Identification Label for a list of the RPOs
used on each specific vehicle.
AA3 Windows - Deep Tint, Side Windows Only
AC2 Window - Sliding, Right Front Door
AD5 Window - Right Rear, Side, Sliding
AD8 Door Check
AE7 Seat - Front, Split
AJ1 Window - Deep Tint, Except Windshield and Doors
AM7 Seat - Right Rear Folding
AP7 Partition - Sliding Plywood
AQ3 Seat - Rear Center
AQ4 Seat - Rear
AS3 Seat - Right Rear, Suburban
AT5 Seat - Center Folding, Suburban
AU2 Lock - Cargo Door
AU3 Power Lock - Side Door
AU6 Power Lock - Tailgate Remote Control
AV5 Seat - High Back, Bucket
AW4 Door - Sliding Side Extension
AX5 Partition - Expanded Metal, Left Side
AX7 Partition - Expanded Metal w/Center Sliding Door
AX9 Latch - Rear Cargo Door
A01 Window - Tinted, All Shaded Windshield
A02 Windshield - Tinted, Shaded Upper
A07 Window - Body
A08 Window - Body, Right Side
A12 Window - Stationary, Back Door
A13 Window - Stationary, Side Rear Door
A17 Window - Left Side Swing-Out
A18 Window - Rear Door, Swing-Out
A19 Glass - Side Rear Door, Swing-Out
A20 Window RR Quarter Vent, Swing Out
A28 Window - Right Rear, Full Width, Sliding
A31 Window - Side, Power
A33 Window - Tailgate, Power
A50 Seat - Front Bucket
A51 Seat - Front Bucket
A52 Seat - Front Bench
A57 Seat - Auxiliary, One Passenger, Folding
A82 Head Restraints
A95 Seat - Front Bucket, High Back, Reclining
BA8 Compartment - Front Seat Storage
BB5 Ornamentation
BF3 Floor Covering - Step Well Mat
BG9 Floor Covering, Rubber
BW2 Ornamentation - Deluxe Body Side Molding
B3D School Bus Equipment
B3J Diesel Equipment
B30 Floor Carpet
B32 Floor Mats - Front
B33 Floor Mats - Rear
B84 Extra Molding - Body Side
B85 Extra Molding - Belt Reveal
B93 Extra Molding - Door Edge Guard
B96 Extra Molding - Wheel Opening
CD4 Wiper System - Pulse
C36 Heater - Auxiliary
C42
C49
C55
C60
C69
C91
C95
DF1
DF2
DG5
D20
D34
D44
D45
D46
D49
D73
D92
E24
E31
E34
E36
E38
E39
E46
E53
E55
E62
E63
E76
E79
E94
F42
F51
F58
F59
F60
G50
G51
G52
G60
G80
KC4
KL7
K05
K09
K22
K34
K46
K60
K68
K81
K99
LB4
LH6
LL4
L03
L05
L19
Heater - Deluxe Outside Air

Defogger - Rear Window, Electric
Vent - Roof
Air Conditioning - Front Manual Controls
Air Conditioner - Roof Mounted
Lamp - Interior Courtesy
Lamp - Interior Courtesy, Dual Reading
Mirror - Camper Type, Painted
Mirror - Camper Type, SST
Mirror - West Coast Type
Sunshade - Windshield, Passenger Side
Mirror - Visor Vanity
Mirror - Outside, Painted
Mirror - Outside, SST
Mirror - West Coast Type with Clearance Lights
Mirror - Chrome
Pickup Box Hand Rail
Stripe - Lower Decor
Door - Cargo Side, Hinged
Body - Steel ,10 ft.
Body - Steel, 10 ft. Standard Width
Body - Aluminum, 10 ft.
Body - Steel, 12 ft. x 8 ft.
Body - Aluminum, 12 ft. x 8 ft.
Door - 66 in., Overhead Sliding w/Window
Door - 87 in., Wrap-Around
End Gate, Suburban
Pickup Box - Stepside (Fenderside)
Pickup Box - Fleetside (Wideside)
Door. - 60 in., Rear
Door ^ 74 in., Rear, Strap Hinges
Rally (Beauville) Equipment
Suspension - Front Heavy Duty
Shock Absorbers - Front and Rear, Heavy Duty
Stabilizer Shaft - Front, Heavy Duty
Stabilizer Shaft - Front
Spring - Front, Heavy Duty
Spring - Rear, Heavy Duty
Spring - Rear, Special Heavy
Spring - Rear 15000 lbs.
Spring - Rear Auxiliary
Axle - Rear, Limited Slip
Engine Oil Cooler System
Gas Conversion - LP
Engine Block Heater
Generator - 120 Amp
Generator - 94 Amp
Cruise Control
Air Cleaner - Heavy Duty, Pre-Cleaner
Generator -100 Amp
Generator - 105 Amp
Generator - 66 Amp
Generator - 85 Amp
Engine - 4.3L V6 TBI
Engine - 6.2L V8, Diesel
Engine - 6.2L V8, Heavy Duty Diesel

LT9
MD8
MY6
M20
M40
M62
M64
NA1
NA4
NA5
NA6
NB2
NE2
NK7
NL2
NL7
NM5
NM8
NY1
N05
N31
N33
N40
N41
N51
N67
N90
PA1
PA6
PF2
P01
P10
P11
P13
P14
P15
P17
QE6
R05
TP2
TR9
TT4
TT5
TVR
T63
T84
T85
UA1
UB4
UD4
UF2
UJ1
UM6
UN3
UY1
UY7
U01
U18
U35
U37
U58
U63
U66
U69
Engine - 5.7L V8 4BBL Heavy Duty

Transmission - Auto. 4 Speed, THM700 R4
Transmission - Manual 4-Speed w/Overdrive
Transmission - Manual 4 Speed, 6.55 1st.
Transmission - Auto, 3 Speed, Torque Conv. Var. 1
Transmission - Manual 3 Speed, 2.85 Ratio
Transmission - Manual 3 Speed. 3.50 Ratio
Emission System - Light Duty
Emission System - Heavy Duty
Emission System - Federal Requirements
Emission System - High Altitude Requirements
Emission System - California Requirements
Fuel Tank - 40 gal.
Fuel Tank - 31 gal.
Fuel Tank - Auxiliary
Fuel Tank - 33 gal.
Emission System - Canadian Requirement
Emission System - Leaded Fuel
Fuel Tank Shield
Fuel Filler Cap Lock
Steering Wheel - Custom
Steering Column - Tilt
Steering - Non-Variable
Steering - Power
Steering - Manual
Wheel - Rally Type
Wheel - Aluminum Cast
Wheel - Trim Discs, Var. 5
Wheel - Styied, Painted
Wheel - 15 x 7 Aluminum
Wheel - Trim Discs, Var. 1
Carrier - Spare Tire
Carrier - Spare Tire, Glide Out
Carrier - Spare Tire, Side-Mounted
Carrier - Inside Mounted Spare Tire, Left Side
Carrier - Inside Mounted Spare Tire, Right Side
Cover - Spare Wheel/Tire
Wheel - 16.5 x 6
Wheel Conversion - Dual Rear
Battery - Auxiliary Camper
Lamp Group
Headlamps - Halogen, Pencil Beam
Headlamps - Haiogen
Lamp - Rear Dome and Reading
Headlamps - Warning System
Headlamps - Right Rule
Headlamps - Left Rule
Battery - High Capacity
Lamps - Rear Side Marker
Alarm - Vehicle Speed
Lamp - Cargo
Indicator System, Brake Warning
Radio - AM/FM Stereo, Seek/Scan, Cassette, Clock
Radio - AM/FM Stereo, Cassette
Wiring Harness - Camper
Wiring Harness - Truck Trailer, Heavy Duty
Lamp - Roof Marker
Speedometer - Kilometer
Electric Clock
Cigarette Lighter
Radio - AM/FM Stereo
R ad io-A M
Speaker System - Dual Front, Dual Rear
R adio-AM /FM
U76
U89
VE5
VF1
VG3
VG5
VR2
VR4
V01
V02
V05
V22
V31
V35
V37
V42
V43
V46
V76
X6W
X6Z
YE9
YG1
YJ6
ZM2
ZW9
ZY1
ZY2
ZY4
Z53
Z62
Z72
Z73
Z75
Z76
Z80
Z81
Z82
12A
12K
12L
12U
15A
18C
18D
181
18V
18W
19A
191
19K
19L
19U
19W
21L
21U
23D
23G
23I
23V
23W
28A
28L
28U
Antenna - Windshield
Wiring Harness - Trailer
Bumper - Front and Rear Impact Strip
Bumper - Rear Chrome
Front Bumper Impact Strip
Rear Bumper Impact Strip
Trailer Hitch
Trailer Hitch - Weight Distributing
Radiator - Heavy Duty
Radiator - Heavy Duty w/Trans. Oil Cooler
Radiator - Heavy Duty
Radiator Grille - Chrome
Bumper Guards - Front, Chrome
Bumper, Rear w/Recessed Lighting
Bumper - Front and Rear Chrome
Bumper - Rear Step, Chrome
Bumper - Rear Step, Painted
Bumper - Front, Chrome
Front Hook Towing Device
Hub - Manual Locking
Hub - Automatic Locking
Equipment Package, Level 3
Molding, Body Side and Wheel Opening
Decor Package - Econo
Trim Package, Bonaventure
Base Body or Chassis
Color Combination - Solid
Color Combination - Two Tone
Color Combination - Deluxe Two Tone
Gage Package - Voltmeter, Oil Press, and Temp.
Equipment Package - Level 1
Trailering Package - L.D. Ball-Type Hitch
Trim - Special Interior
Shock Absorbers - Four Front
Special Chassis - Camper Package
Trim - Special Exterior
Camper - Special
Trailer Hitch - Special Reese Type
Stripe Accent - White
Color Combination - White (Auxiliary Top)
Secondary Color - White
Primary Color - White
Stripe Accent - Grey
Trim Combination - Charcoal, Stnd Cloth
Trim Combination - Charcoal, Velour Cloth
Interior Trim - Charcoal
Trim Combination - Charcoal, Vinyl Striped
Trim Combination - Charcoal, Dual Grain Vinyl
Stripe Accent - Black and Grey Two Tone
Interior Trim - Black
Color Combination - Black (Auxiliary Top)
Secondary Color - Black
Primary Color - Black
Trim Combination - Black, Dual Grain Vinyl
Secondary Color - Lt. Blue Metallic
Primary Color - Lt. Blue Metallic
Trim Combination - Blue, Velour Cloth
Trim Combination - Blue Cloth
Interior Trim - Blue Vinyl
Trim Combination - Blue Vinyl, Striped
Trim Combination - Blue Dual Grain Vinyl
Stripe Accent - Dk Blue and Lt Blue
Secondary Color - Dk. Blue Metallic
Primary Color - Dk. Blue Metallic

29A
29K
29L
29U
55L
55U
61K
61L
61U
62C
62D
62G
62I
62V
62W
66K
66L
66U
67L
67U
72A
72L
72U
Stripe Accent - Dk. and Lt. Blue

Color Combination - Dk. Blue (Auxiliary Top)
Secondary Color - Dk. Blue
Primary Color - Dk. Blue
Second Color - Russet Metallic
Primary Color - Russet Metallic
Color Combination - Tan (Auxiliary Top)
Secondary Color - Tan
Primary Color - Tan
Trim Combination - Lt. Saddle, Stnd. Cloth
Trim Combination - Lt. Saddle, Velour Cloth
Trim Combination - Saddle Cloth
Interior Trim - Lt. Saddle
Trim Combination - Lt. Saddle Vinyl, Striped
Trim Combination - Lt. Saddle, Dual Grain Vinyl
Color Combination - Dk. Brown
Secondary Color - Dk. Brown Metallic
Primary Color - Dk. Brown Metallic
Secondary Color - Lt. Saddle Metallic
Primary Color - Lt. Saddle Metallic
Stripe Accent - Bright Red
Secondary Color - Bright Red
Primary Color - Bright Red
76C
76D
76G
76I
76V
76W
77C
77D
77G
77I
77V
77W
78U
82D
82G
82I
82W
90K
90L
90U
93U
9V8
Trim Combination - Bronze, Stnd. Cloth

Trim Combination - Bronze, Velour Cloth
Trim Combination - Dk. Claret and Gold, Garnet Red
Interior Trim - Bronze
Trim Combination - Bronze, Striped Vinyl
Trim Combination - Bronze, Dual Grain Vinyl
Trim Combination - Dk. Maple, Stnd. Cloth
Trim Combination - Dk. Maple, Velour Cloth
Trim Combination - Dk. Maple Cloth
Interior Trim - Dk. Maple
Trim Combination - Dk. Maple, Striped Vinyl
Trim Combination - Dk. Maple, Dual Grain Vinyl
Primary Color - Med. Rosewood Metallic
Trim Combination - Med. Dk. Grey Velour Cloth
Trim Combination - Med. Dk. Grey Cloth
Interior Trim - Med. Dk. Grey
Trim Combination - Dk. Grey, Dual Grain Vinyl
Color Combination - Med. Grey (Auxiliary Top)
Secondary Color - Grey Metallic
Primary Color - Grey Metallic
Primary Color - Lt. Driftwood Pearlmist
Color Combination - Cardinal Red
OB-1
SECTION OB
MAINTENANCE AND LUBRICATION

CONTENTS
SUBJECT
PAGE
Capacities......................................................................................................................................................................... 08-1
Lubrication....................................................................................................................................................................... 08-6
Maintenance S cheduie...................................................................................................................................................OB-7
CAPACITIES
Figures 2 through 6 show the approximate capacities of the differential
gear, the transmission, the cooling system, the crankcase, the fuel tank, the
front axle and the transfer case. Engine code letters are used in the charts.
Refer to figure 1 for an explanation of the code.
ENGINE DESCRIPTION
VIN
Engine Code
Liter
Displacement
Z
H
K
M
N
W
T
C
J
4.3
5.0
5.7
5.7
7.4
7.4
4.8
6.2
6.2
Type
Fuel
System
Produced
In
V6
V8
V8
V8
V8
V8
L6
V8
V8
TBI
TBI
TBI
4 BBL
TBI
4 BBL
1 BBL
F.l. @
F.l. @
USA
USA, Can.
USA, Can.
USA, Can.
USA
USA
Mexico
USA
USA
Figure 1 1987 Engine Code Identification
Metric
Measure
Items
U.S.
Measure
Differential
8 V2" Ring Gear
9 V2" Ring Gear
IOV2" Ring Gear (Chev.)

93/4" Ring Gear (Dana)
12 Ring Gear (Rockwell)

Transmission
Automatic
400 Pan Removal
Overhaul
700-R4 Pan Removal
Overhaul
Manual
4 Speed 117 mm
4 Speed 89 mm
3 Speed 76 mm
2.0
3.1
3.1
2.8
5.9
L
L
L
L
L
4.2 pts.
6.5 pts.
6 V2 pts.
6.0 pts.
12.5 pts.
4.0 L
10.0 L
4.7 L
10.9 L
9.0 pts.
10.0 pts.
23.0 pts.
4.0 L
4.0 L
1.5 L
4.2 qts.
4.2 qts.
1.6 qts.
22.0 pts.
Figure 2Approximate CapacitiesAll Models
OB-2 MAINTENANCE AND LUBRICATION
CAPACITIES
Items
Cooling System (Approx.)
Code: H, K, M
Without A/C
With A/C
Code: N
Without A/C
With A/C
Diesel Engines
Code: C, J
With or Without A/C
Crankcase*
Gasoline Engines
Code: H, K and M
Without Filter
With Filter
Code: N
Without Filter
With Filter
Diesel Enginesf
Code: C, J With Filter
Metric
Measure
U.S.
Measure
16.5 Liters
17 Liters
17.5 Quarts
18 Quarts
22 Liters
23 Liters
23 Quarts
24.5 Quarts
23 Liters
25 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
6.5 Liters
7 Quarts
Fuel Tank (Approx.)

Standard, All Gas
Diesel
NK7 Option, All Gas
Diesel
NE2 Option, Suburban Only
Gas
Diesel
95 Liters
102 Liters
117 Liters
121 Liters
25
27
31
32
151 Liters
155 Liters
40 Gallons
41 Gallons
Front Axle
V15/10-V25/20
V35/30
1.9 Liters
2.8 Liters
2 Quarts
3 Quarts
Transfer Case
V15/10-V25/20
V35/30
4.9 Liters
2.4 Liters
5.2 Quarts
2.5 Quarts
Gallons
Gallons
Gallons
Gallons
After refill, fluid level must be checked as outlined under Service and
Maintenance, in Section 5 of this manual,
t Oil filter should be changed at EVERY oil change.
A Equipped with Auxiliary Heater add 2.68L/2.84 Qts.
Figure 3Approxim ate C apacities-B lazer/Jim m y, Suburban
MAINTENANCE AND LUBRICATION OB-3
CAPACITIES
Items
Cooling System (approx.)
4.8L (L6) Engine Code T
P30042 Models
With or Without A/C
5.7L (V8) Engine Code M, K
P30042 Models
With or Without A/C
7.4 L (V8) Engine Code W
P30032 Models
Without A/C
6.2L (V8) Diesel Engine Code J
P30042 Models
With or Without A/C
P30032 Models
Without A/C
Crankcase (approx.)*
Engine Code: M, K
Without Filter
With Filter
Engine Code: T
Without Filter
With Filter
Engine Code: W
Without Filter
With Filter
Engine Code: J f
With Filter
Fuel Tank Data
P25-35
P30042 School Bus
P30032 Motor Home*
Metric
Measure
U.S.
Measure
13.1 Liters
13.8 Quarts
14.6' Liters
15.5 Quarts
21.2 Liters
22.5 Quarts
23.5 Liters
25 Quarts
23.4 Liters
24.7 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
5.7 Liters
* 6.5 Liters
6 Quarts
7 Quarts
6.5 Liters
7 Quarts
151 Liters
151 Liters
151 Liters
40 Gallons
40 Gallons
40 Gallons
* After refill, fluid level should be checked as outlined under Service and
Maintenance, in Section 5 of the Owners Manual.
t Oil Filter should be changed at EVERY oil change.
Optional 60 gallon fuel tank available.
Figure 4Approxim ate C apacities-Forw ard Control
CAPACITIES
Items
Cooling System (Approx.)
Code: Z - V6
With or Without A/C
Code: H, KV-8
Without A/C
With A/C
Code: N-V-8
Without A/C
With A/C
Diesel Engines
Code: C, J
With or Without A/C
CrankcaseA
Gasoline Engines
Code: H, K, Z
Without Filter
With Filter
Code: T
Without Filter
With Filter
Code: N
Without Filter
With Filter
Diesel Engines!
Code: C, J
Metric
Measure
U.S.
Measure
10.3 Liters
10.9 Quarts
16.5 Liters
17 Liters
17.5 Quarts
18 Quarts
22 Liters
23 Liters
23 Quarts
24.5 Quarts
23 Liters
25 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
6.5 Liters
7 Quarts
Fuel Tank (Approx.)

Long Bed
Single Tank, Gas
@*Dual Tanks, Gas
Single Tank, Diesel
*Dual Tanks, Diesel
76
61
76
76
Front Axle
V15/10-V25/20
V35/30
1.9 Liters
2.8 Liters
2 Quarts
3 Quarts
Transfer Case
V15/10-V25/20
V-35/30
4.9 Liters
2.4 Liters
5.2 Quarts
2.5 Quarts
Liters
Liters
Liters
Liters
20
16
20
20
Gallons
Gallons
Gallons
Gallons
AAfter refill, fluid level must be checked as outlined under Service and
Maintenance, in Section 5 of the Owners Manual,
t Oil filter should be changed at EVERY oil change.
* Listed quantity is for each tank.
@Above 8600 GVWR Both tanks 76 liters, 20 gallons.
Figure 5Approxim ate C apacities-P ickup Models
CAPACITIES
Metric
Measure
US
Measure
10.5 L
11 Qts.
16'L
16 L
23 L
24.2 L
17 Qts.
17 Qts.
24 Qts.
25.5 Qts.
Crankcase (Approx.)*
All engines except diesel
Without Filter
With Filter
Diesel Engines With Filter
3.8 L
4.8 L
6.5 L
4 Qts.
5 Qts.
7 Qts.
Fuel Tank (Approx.)

Gasoline and Diesel Engines
Standard
Optional
83 L
125 L
22 Gal.
33 Gal.
Item
Cooling System (Approx.)A
4.3 L (Z)
V8s Except Diesel
Without A/C
With A/C
6.2 L (C) Diesel
6.2 L (J) Diesel
* After refill, fluid level should be checked as outlined under Service and
Maintenance Section 5 of the Owners Manual.
A If equipped with Auxiliary Heater add 2.68L/2.84 Qts.
t Oil Filter should be changed at EVERY oil change.
Figure 6Approxim ate C apacities-G Van
LUBRICATION
Figures 7, 8 and 9 show chassis lubrication points for the R, V, G and P chassis.
1.
2.
3.
4.
5.
6.
7.
8.
L ow er C o n tro l A rm s
U p p e r C o n tro l A rm s
U p p e r and L o w e r C o n tro l A rm Ball J o in ts
In te rm e d ia te S te e rin g S h a ft (PA10)
T ie Rod E nds
W h e el B e a rin g s
S te e rin g G ear
A ir C le a n e r - E le m e n t
9. M a s te r C y lin d e r
10. T ra n s m is s io n - M an ua l
- A u to m a tic
11. T h ro ttle B ell C ra n k - L6
12. C a rb u re to r L in k a g e - V8
13. Brake and C lu tc h Pedal S p rin g s
14. U nive rsa l J o in ts
15. Rear A x le
F-00433
F igure 7 L u b ric a tio n P o ints For The C on ven tion a l A nd F orw ard C o n tro l M odels
1.
2.
3.
4.
5.
6.
7.
A ir C le a n e r
C o n tro l L in k a g e P o in ts
T ie Rod E nds
W h e el B e a rin g s
S te e rin g G ear
M a s te r C y lin d e r
T ra n s m is s io n - M an ua l
- A u to m a tic
8.
9.
10.
11.
12.
13.
14.
15.
C a rb u re to r L in k a g e - V8
U nive rsa l J o in ts
P ro p e lle r S h a ft S lip J o in ts
F ro n t and Rear A x le
Drag L in k
Brake and C lu tc h Pedal S p rin g s
T ra n sfer C ase
T h ro ttle B ell C ra nk - L6
F-00434
Figure 8Lubrication Points For The RV Four Wheel Drive Models
1
1. C o n tro l A rm B u s h in g s and Ball J o in ts
2. T ie Rod E nds
3. W h e el B e a rin g s
4. S te e rin g G e ar C lu tc h C ro s s -S h a ft
5 11
5. T ra n s m is s io n C o n tro l S h a ft
6. A ir C le a n e r - E le m e n t
7. T ra n s m is s io n - M anual
- A u to m a tic
8.
9.
10.
11.
Rear A x le
O il F ilte r
Brake M a s te r C y lin d e r
P arking Brake L in k a g e
F-00435
Figure 9Lubrication Points For The G Van
The information shown on pages OB-8 through OB-25 is the same as shown in the 1987 Light Duty Maintenance
Schedule and Log.
1987
GENERAL MOTORS
LIGHT DUTY TRUCK
MAINTENANCE SCHEDULES
This booklet covers the maintenance required for your General Motors vehi
cle. It is essential that your vehicle receive this maintenance to retain the
safety, dependability, and emission control performance originally built into
your vehicle.
Maintenance service should be done by your General Motors truck

dealer or any other qualified automotive service or repair establishment
which is able to provide such services and which can be relied upon to
use proper parts and practices.
In addition to the in-shop type services shown in Sections A and B, this
booklet also includes owner inspections and services in Section C which you
or a qualified technician should perform periodically.
Always keep this booklet in your vehicle, and leave it with the vehicle
when sold. The maintenance record, plus maintenance receipts, may be
needed for warranty repairs. It is suggested that receipts be kept with
this booklet.

SELECTING YOUR VEHICLES
MAINTENANCE
DETERMINING VEHICLE EMISSIONS
CLASSIFICATION
To determine the emissions classification for your vehicle, refer to the En
gine Emission Classification by VIN Code chart. This chart classifies your
engine as a Light Duty Emissions Engine or Heavy Duty Emissions Engine
using the engine code identifier of the Vehicle Identification Number (VIN).
The VIN is located on the plate on the top left corner of the instrument
panel. (It is also on the Certification Label and the Service Parts Identification
Label.) The Engine Code is the eighth character in this number. Locate your
vehicles Engine Code on the following Engine Emission Classification Chart
to determine your vehicles emissions class.
ENGINE EMISSION CLASSIFICATION

BY VIN CODE
Engine D escription
Engine D ispl./Type
2.5L L4rTBI
2.8L V6/TBI
4.3L V6/TBI
4.8L L6/Carbureted
5.0L V8/TBI
5.7L V8/TBI
5.7L V8/Carbureted
6.2L V8/Diesel
6.2L V8/Diesel
7.4L V8/TBI
7.4L V8/Carbureted
VIN Code
RPO
L ight Duty
Em issions
LN8
LL2
LB4
L25
L03
L05
LT9
LL4
LH6
L19
LE8
NOTE: TBI is a throttle body injection system.
Heavy Duty
Em issions
E
R
Z
T
H
K
M
J
C
N
W

SELECTING THE PROPER
MAINTENANCE CHART
Select the proper maintenance from pages 6 through 13 depending on your
vehicles engine (gas or diesel) and engine emissions classification.
SELECTING THE PROPER

MAINTENANCE SCHEDULE
Select and follow either Maintenance Schedule 1 or Maintenance Schedule 2
based on how you use your vehicle.
MAINTENANCE SCHEDULE 1
Follow Maintenance Schedule 1 denoted by a white circle (O) if you mainly
operate your vehicle under one or more of the following conditions:
When most trips are less than 4 miles (6 kilometers).
When most trips are less than 10 miles (16 kilometers) and outside tem
peratures remain below freezing.
Towing a trailer.
Operating in dusty areas.
Idling and/or low-speed operation in stop-and-go traffic.
NOTE: Schedule 1 should also be followed if the vehicle is used for delivery
service, police, taxi, or other commercial applications.
MAINTENANCE SCHEDULE 2
Follow Maintenance Schedule 2 denoted by a black circle ( ) only if none of
the driving conditions specified in Maintenance Schedule 1 apply.
0B-10
SECTION A -S C H E D U LE D MAINTENANCE SERVICES FOR YOUR 1987 VEHICLE
Item
Miles (000)
No. Service
Kilometers (000)
12
5 10
o o#
15 20
o om
Oil Filter Change *
o 0*
2A Chassis Lubrication
o 0#
om
1 Engine Oil Change *
o Maintenance Schedule 1
Maintenance Schedule 2
15 18 21 24 27 30
25 30 35 40 45 50
o o # o om o o
o o# o
o
o om
o
o*
om
33
36
55 60
o o*
o
om
39
42
65 70
o o#
o om
o
om
45
48
75 80
o om
o
o
o
om
om
2B Clutch Fork Ball Stud

3 Engine Idle Speed Adjustment * - At First 6 Months or,
- Refer to Page 9
- Refer to Page 9
09
om
om
om
5 Air Cleaner, A.I.R. and PCV Filter Replacement A *
om
om
om
om
om
om
7 Transmission Service - Refer to Section B

for Service Intervals
8A PCV System Inspection *
9 Fuel Filter Replacement *
om
o
om
om
o
om
om
11 Vacuum Advance System Inspection *

o1
o#1
om2
o1
o*1
O * 1'2
o2
13 Spark Plug Wire Inspection *

14 EGR System Inspection *
o*1
o#1
16 Engine Timing Check * A
o*
o*
FOOTNOTES:
* An Emission Control Service
A Also a Noise Emission Control Service
Applicable only to vehicles sold in the United States
t To determine the emissions classification of your engine refer to page 4.
1. For vehicles using leaded fuel.
2. For vehicles using unleaded fuel.
60
100
om
10 Carburetor Choke and Hoses Inspection *

12 Spark Plugs *
57
95
o
om
o
4 Cooling System Service * - Every 24 Months or

6 Front Wheel Bearing Repack
51 54
85 90
o om
o om
om
The maintenance services contained in Maintenance Schedule 1 and 2 are based on

the assumption that your vehicle will be used as designed:
To carry passengers and cargo within the limits shown on the tire placard located
on the edge of the drivers door.
On reasonable road surfaces within legal driving limits.
With the proper fuels specified for your vehicle.
The services shown in this schedule up to 60,000 miles (100 000 km)
are to be performed after 60,000 miles (100 000 km) at the same intervals.
WITH HEAVY DUTY EMISSIONS - GASOLINE ENGINES t
(Continued
SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1987 VEHICLE WITH HEAVY DUTY EMISSIONS - GASOLINE ENGINES t
Miles (000)
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
Kilometers (000)
10
15
20
25
30
35
40
o
45
50
55
60
65
70
75
80
o
85
90
95
100
Item
No. Service
o Maintenance Schedule 1 - Refer to Page 9

Maintenance Schedule 2 - Refer to Page 9
17 Fuel Tank, Cap and Lines Inspection *

18 Early Fuel Evaporation System Inspection *
19 Thermostatically Controlled Air Cleaner Inspection * A
20 Engine Accessory Drive Belts Inspection *
om
om
om
om
om
om
om
om
o
09
om
om
om
om
23 Air Intake System Inspection A

24 Thermostatically Controlled Engine Cooling Fan Check
A " - Every 12 Months or
om
o
o
om
om
21 Evaporative Control System Inspection *

22 Shields and Underhood Insulation Inspection A
09
om
om
om
om
25 Manifold Heat Valve Check A *
om
om
26 Idle Speed Control Device * - Every 12 Months or
om
om
27 Throttle Return Control Check * Every 12 Months or
om
om
28 Engine Idle Mixture Adjustment (4.8 L only) *

29 Governor Check A - Every 48 Months or
o
om
om
31 Tire Rotation - Refer to Section B

FOOTNOTES:
Also a Noise Emission Control Service
1. For vehicles using leaded fuel.
2. For vehicles using unleaded fuel.

With the proper fuels specified for your vehicle.
om
OB-11
1987 VEHICLE WITH A 6.2 L DIESEL ENGINE t
Miles (000)
No. Service
Kilometers (000)

Oil Filter Change *
3 Engine Idle Speed Adjustment *
4 Cooling System Service * Every 24 Months or
2.5
7.5
12
o o#
o o
o 09
o
o
o
o Maintenance Schedule 1 - Refer to Page 9

Maintenance Schedule 2 Refer to Page 9
10 12.5 15
16 20 24
09
09
09
o
o
o
09
17.5 20 22.3 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60

28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96
o 09 o o o 09 o o # o 09 o o # o 09 o o # o 09
09
o 09
09
09
o o#
o 09
o 09
o 09
o o*
o 09
09
o 09
09
o 09
09
o1
5 Air Cleaner Element Replacement* 2

09
09
09
09
09
09
O *1
09
09
09
o1
09
09
09

8B CDRV System Inspection *
09
20 Drive Belts Inspection
09
22 Shields and Underhood Insulation Inspection
09
09
09
09
09
09
23 Air Intake System Inspection
09
09
09
09
09
09
24 Thermostatically Controlled Engine

Cooling Fan Check A Every 12 Months or
09
09
09
09
09
09
30 Exhaust Pressure Regulator Valve Inspection *
09
31 Tire Rotation - REfer to Section B

FOOTNOTES:
1. In California, thes6 are the minimum Emission Control Maintenance Services an owner
must perform according to the California Air Resources Board. General Motors, how
ever, urges that all Emission Control Maintenance Services shown be performed. To
maintain your other new vehicle warranties, all services shown in this booklet should
be performed.
2. For vehicles with engine VIN Code J (RPO LL4), replace element every 15,000 miles
(24 000 km).
Applicable only to trucks sold in the United States.
Also, a Noise Control Service (applicable to vehicles with engine VIN Code J
(RPO LL4).
t This maintenance schedule applies to all diesel emission classifications.
NOTE: Refer to Section 0 of your owners manual for VIN code identification information.
The maintenance services contained in Maintenance Schedule 1 and 2 are based

on the assumption that your vehicle will be used as designed:
To carry passengers and cargo within the limits shown on the tire placard
located on the edge of the drivers door.
With No. 1, blend or No. 2 grade diesel fuel.
Item
OB-12
SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR
1987 VEHICLE WITH LIGHT DUTY EMISSIONS - GASOLINE ENGINES t
SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR

Miles (000) 3
6 7.5 9 12
Item
Kilometers (000) 5 10 12.5 15 20
No. Service
Oil Filter Change *
o
o
o
o
o
o
o
o
o
o
o
o
o Maintenance Schedule 1
Maintenance Schedule 2
15 18 21 22.5 24 27 30
25 30 35 37.5 40 45 50
- Refer
- Refer
33 36
55 60
o
09
o 09
09
o 09

4 Cooling System Service * Every 24 Months or
to Page 9
to Page 9
37.5 39 42 45 48 51 52.5 54 57 60
62.5 65 70 75 80 85 87.5 90 95 100
o 09
o 09
o
o
o
o
o o
o o
o o*
09
09
09
09
o1
5 Air Cleaner Element*

O
O#
09

for Service Interval
8A PCV System Inspection *
09
12 Spark Plugs *
09
o1
09
13 Spark Plug Wire Inspection*
09
15 Electronic Vacuum Regulator Valve

(EVRV) Inspection *
09
09
16 Engine Timing Check *

O
17 Fuel Tank, Cap and Lines Inspection *
09
09
20 Engine Accessory Drive Belts Inspection *

31 Tire Rotation
FOOTNOTES:
1. In California, these are the minimum Emission Control Maintenance Services an owner
must perform according to the California Air Resources Board. General Motors, how
ever, urges that all Emission Control Maintenance Services shown be performed. To
maintain your other new vehicle warranties, all services shown in this booklet should
be performed.
09
09

With unleaded fuel.
9 Fuel Filter Replacement *
OB-13
SECTION B EXPLANATION OF
SCHEDULED MAINTENANCE SERVICES
The services listed in the preceding Maintenance Schedules are further
explained below. After services are completed, fill in the Maintenance Record
at the end of this booklet. When the following maintenance services are per
formed, make sure all parts are replaced and all necessary repairs are done
before operating your vehicle. Be sure to use the proper fluids and lubricants
as shown in Section E.
Item No.
1. ENGINE OIL AND OIL FILTER CHANGE * ALWAYS USE SF/CC or
SF/CD QUALITY, ENERGY CONSERVING OILS OF THE PROPER
VISCOSITY Also always change oil and filter as soon as possible after
driving in a dust storm. Refer to Section 5 of your Owners Manual for
further details.
2A. CHASSIS LUBRICATION Lubricate the front suspension (except
when equipped with maintenance-free ball joint), steering linkage,
transmission, clutch, and transfer case shift linkage, parking brake ca
ble guides, propshaft, universal joints, brake pedal springs, and clutch
pedal springs. On vehicles without hydraulic clutches lubricate clutch
cross shaft every 30,000 miles (50 000 km).
2B. CLUTCH FORK BALL STUD Refer to the Service Parts Identifica
tion Label located on the inside of the glove box. Match the three digit/
RPO code to the appropriate RPO code below. Follow the maintenance
as detailed for your particular vehicle.
RPO codes: MC0, MG5, M20, MY6, M62, M64 Lubricate the clutch
fork ball stud through the fitting on the clutch housing found on some
models. Lubricate this bail stud sparingly, as too much lubrication
may cause problems with the clutch assembly.
3. ENGINE IDLE SPEED ADJUSTMENT (CARBURETED ENGINES
ONLY) * Adjust to the specifications shown on the underhood label.
You must use calibrated test equipment. Check that idle stop solenoid
or dashpot work properly (if so equipped).
4. COOLING SYSTEM SERVICE * Drain, flush and refill system with
new coolant. Refer to Section 5 of your Owners Manual for further
details.
5. AIR CLEANER ELEMENT REPLACEMENT, A.I.R. AND PCV FILTER
REPLACEMENT (SOME MODELS) * Replace at specified intervals.
Replace more often under dusty conditions. Ask your dealer for the
proper replacement intervals for your driving conditions.
6. FRONT WHEEL BEARING REPACK Clean and repack the front
wheel bearings at each brake relining, or at the specified interval,
whichever comes first.
14
7. TRANSMISSION SERVICE
A utom atic Transm ission Change the transmission fluid and filter
every 15,000 miles (25 000 km) for vehicles under 8600 GVWR or every
12.000 miles (20 000 km) for vehicles over 8600 GVWR if the vehicle is
mainiy driven under one or more of these conditions:
In heavy city traffic where the outside temperature regularly
reaches 90F (32C) or higher.
In hilly or mountainous terrain.
Frequent trailer pulling.
Uses such as taxi, police, delivery or other commercial service.
If the vehicle is not used mainly under any of these conditions, change
the fluid and filter every 30,000 miles (50 000 km) for vehicles under
8600 GVWR or every 24,000 miles (40 000 km) for vehicles over 8600
GVWR. Refer to Section 5 of your Owners Manual for further details.
Manual Transm ission Refer to the Service Parts Identification Label
located on the inside of the glove box. Match the three digit/RPO code
to the appropriate RPO code below. Follow the maintenance schedule
recommended for your particular transmission.
RPO Code:
M73 (4-Speed)
Change transmission fluid at 7,500 miles (12 500 km), then every
30.000 miles (50 000 km).
RPO Codes:
M62 and M64 (3-Speed)
M20, MCO, MC9, and MF2 (4-Speed)
MY6 (4-Speed Overdrive)
ML2, ML3, MH3 (5-Speed)
MG5 (5-Speed Overdrive)
Transmission fluid does not require periodic changing.
8A. PCV SYSTEM INSPECTION * Check that PCV (Positive Crankcase
Ventilation) system works properly. Replace the valve and any worn,
plugged or collapsed hoses as necessary.
8B. CDRV System Inspection * Check the Crankcase Depression Reg
ulator Valve System for any worn, plugged or collapsed hoses. Have
the system checked as described in the Service Manual.
9. FUEL FILTER REPLACEMENT * Replace the fuel filter at the speci
fied interval or sooner if clogged.
10. CARBURETOR CHOKE AND HOSES INSPECTION * Verify that
choke and vacuum break work properiy and within specifications. Cor
rect any binding caused by damage or gum on the choke shaft. Inspect
hoses for proper hookup, cracks, chafing, or decay. Correct as neces
sary.
15
11. VACUUM ADVANCE SYSTEM INSPECTION * Check that the systern works properly. Check hoses for proper hookup, cracks, chafing or
decay. Replace parts as needed.
12. SPARK PLUGS * Replace spark plugs with the type listed in Sec
tion 6 of your Owners Manual.
13. SPARK PLUG WIRE INSPECTION * Clean wires and inspect for
burns, cracks or other damage. Check the wire boot fit at the distributor
and at the spark plugs. Replace wires as needed.
14. EGR SYSTEM INSPECTION * Conduct EGR SYSTEM CHECK as
referenced in the Maintenance and Lubrication Section of the Service
Manual.
15. ELECTRONIC VACUUM REGULATOR VALVE (EVRV) INSPECTION
* Inspect filter for excessive contamination or plugging. If required,
clean element with a solution of biodegradable soap and water, let dry
and reinstall element.
16. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK (SOME
MODELS)* Adjust timing to underhood label specifications. Inspect
the inside and outside of the distributor cap and rotor for cracks, carbon
tracking and corrosion. Clean or replace as needed.
17. FUEL TANK, CAP AND LINES INSPECTION * Inspect the fuel
tank, cap and lines for damage or leaks. Remove fuel cap, inspect
gasket for an even filler neck imprint, and any damage. Replace parts
as needed.
18. EARLY FUEL EVAPORATION (EFE) SYSTEM INSPECTION *
Check that valve works properly; correct any binding. Check that ther
mal vacuum switch works properly. Check hoses for cracks, chafing, or
decay Replace parts as needed.
19. THERMOSTATICALLY CONTROLLED AIR CLEANER INSPECTION
* (If so equipped.) Inspect all hoses and ducts for proper
hookup. Make sure valve works properly.
20. ENGINE ACCESSORY DRIVE BELTS INSPECTION * Inspect belts.
Look for cracks, fraying, wear, and proper tension. Adjust or replace as
needed.
21. EVAPORATIVE CONTROL SYSTEM (ECS) INSPECTION * Check
all fuel and vapor lines and hoses for proper hookup, routing, and con
dition. Check that bowl vent and purge valves work properly, if
equipped. Remove canister, and check for cracks or damage. Replace
as needed.
22. SHIELDS AND UNDERHOOD INSULATION INSPECTION A In
spect shields and underhood insulation for damage or looseness. Ad
just or replace as required.
AAlso a Noise Emission Control Service
16
23. AIR INTAKE SYSTEM INSPECTION

Check the air intake system installation to see that gaskets are seated properly and all hose
connections, fasteners, and other components are tight. Also check to
be sure that the air cleaner housing is properly seated, that the cover
fits tightly, and the wingnut(s) is tight. Tighten connections and fasten
ers or replace damaged parts as required.
24. THERMOSTATICALLY CONTROLLED ENGINE COOLING FAN IN
SPECTION A (If so equipped.) With the engine o ff and below
normal operating temperature, check to see that the fan can be rotated
by hand on fluid coupling or viscous drives. Replace as necessary.
25. MANIFOLD HEAT VALVE CHECKA Some engines are equipped
with a manifold heat valve which should be inspected and repaired as
necessary to insure free operation.
26. IDLE SPEED CONTROL DEVICE * Check that parts work properly.
Replace them as needed.
27. THROTTLE RETURN CONTROL (TRC) SYSTEM INSPECTION * Inspect hoses for proper connections, cracking, abrasion, or deteriora
tion and replace as necessary. Check for proper operation of system.
Check for shorted or broken wires and ensure electrical connectors are
fully engaged at distributor, speed switch and vacuum solenoid.
28. ENGINE IDLE MIXTURE ADJUSTMENT (4.8 L ONLY) * At desig
nated intervals or in case of a major carburetor overhaul, or when poor
idle quality exists, adjust mixture by a mechanical method (lean drop),
following the specifications shown on the label under the hood.
29. GOVERNOR CHECK A > (If so equipped). Check the engine noload governed speed and reset to specifications as required.
30. EXHAUST PRESSURE REGULATOR VALVE INSPECTION *
Check that valve works properly. Correct any binding. Inspect hoses for
cracks, chafing or decay. Replace parts as needed.
31. TIRE ROTATION AND WHEEL INSPECTION Rotate your tires at
the specified maintenance service interval as follows:
Schedule 1 (O) Every 6,000 miles (10 000 km).
Schedule 2 ( ) Every 7,500 miles (12 500 km).
Inspect tires and wheels for abnormal wear or damage. Refer to Sec
tion 5, Tires in your Owners Manual for further information. For dual
wheels, whenever the vehicle, wheels, or fasteners are new, have the
wheel fastener torque set at the first 100,1,000, and 6,000 miles (160,
1 600, and 10 000 km).
AAlso a Noise Emission Control Service
17
SECTION C OWNER
INSPECTIONS AND SERVICES
Listed below are inspections and services which should be made by either
you or a qualified technician at the intervals shown to help ensure proper
safety, emission performance and dependability of your vehicle. Take any
problems promptly to your dealer or another qualified technician for service
advice. Whenever repairs are necessary, have them completed at once. For
your safety and that of others, any safety-related parts that could have been
damaged in an accident should be inspected, and all needed repairs should
be done before operating your vehicle. Be sure to use the proper fluids and
lubricants as shown in Section E.
WHILE OPERATING YOUR VEHICLE

Autom atic transm ission sh ift indicator operation Make sure the indi
cator points to the gear chosen.
Horn operation Blow the horn occasionally to make sure it works.
Check all button locations.
Brake system operation Be alert to abnormal sounds, increased brake
pedal travel or repeated pulling to one side when braking. Also, if a brake
warning light goes on, something may be wrong with part of the brake sys
tem.
Exhaust system Be alert to any changes in the sound of the system or
any smell of fumes. These are signs the system may be leaking or overheat
ing. Have it inspected and repaired at once. Also, refer to Section 2 Engine
Exhaust Gas Caution (Carbon Monoxide), and Section 5 Catalytic Con
verter in your Owners Manual.
Tire and wheel Be alert to a vibration of the steering wheel or seat at
normal highway speeds. This may mean a wheel balance is needed. Also, a
pull right or left on a straight, level road may show the need for a tire pressure
adjustment or wheel alignment.
Steering system operation Be alert to changes in steering action. An
inspection is needed when the steering wheel is harder to turn or has too
much free play or if abnormal sounds are noted when turning or parking.
Headlight aim Take note of the light pattern occasionally. If beam aim
doesnt look right, headlights should be adjusted.
AT EACH FUEL FILL

Engine oil level check t Check engine oil level and add if necessary.
Refer to Section 5 of your Owners Manual for further details.
t A large loss in these systems may indicate a problem. Have them in
spected and repaired at once.
18
Engine coolant level ana co ndition f Check engine coolant level in

coolant reservoir tank and add if necessary. Replace if dirty or rusty. Refer to
Section 5 of your Owners Manual for further details.
W indshield washer flu id level check Check washer fluid level in con
tainer and add if necessary.
Hood latch operation When opening hood, note the operation of sec
ondary latch. It should keep hood from opening all the way when primary
latch is released. Make sure that hood closes firmly.
AT LEAST MONTHLY
Tire pressure check and wheel inspection Keep pressures as shown
on Tire Placard on the drivers door (including spare). Pressure should be
checked when tires are cold. Inspect tires and wheels for abnormal wear or
damage. Refer to Section 5, Tires inyour Owners Manual for further infor
mation.
L ight operation check Check operation of license plate light, side
marker light, headlights including high beams, parking lights, taillights, brake
lights, turn signals, backup lights, instrument panel illumination and hazard
warning flashers.
Fluid leak check After the vehicle has been parked for a while, inspect
the surface beneath the vehicle for water, oil, fuel or other fluids. Water drip
ping from the air conditioning system after use is normal. If you notice fuel
leaks or fumes, the cause should be found and corrected at once.
AT LEAST TWICE A YEAR

(FOR EXAMPLE, EVERY SPRING AND FALL)
Power steering pump level check t Check power steering pump fluid
in accordance with the instructions in Section 5 of your Owners Manual and
add fluid if necessary.
Brake m aster cylinder reservoir flu id level check t Check fluid level
in accordance with the instructions in Section 5 of your Owners Manual, and
add fluid if necessary. A low fluid level can indicate that worn disc brake pads
may need to be serviced.
Clutch pedal free travel (except hydraulic clutch) Check the clutch
pedal free travel. The free travel should be about one inch. Adjust linkage
whenever there is little or no free travel.
Key lock cylinder Lubricate key iock cylinders. Lock deicers which con
tain alcohol may wash away lubricants. It is recommended that you lubricate
the lock cylinder after you have used a deicer of this type. Refer to Section E
in this booklet for the proper luDricants.
spected and repaired at once
19
0B-20 MAINTENANCE AND LUBRICATION
W eatherstrip lubrication Clean surface and then apply a thin film of

silicone grease with a clean cloth.
EACH TIME OIL IS CHANGED

Autom atic or manual transm ission flu id level check f Check trans
mission fluid level and add as required. Refer to Section 5 of your Owners
Manual for further details.
Steering and suspension t Inspect front and rear suspension and
steering system for damaged, loose or missing parts, signs of wear or lack of
lubrication. Inspect power steering lines and hoses for proper hookup, bind
ing, leaks, cracks, chafing, etc. (On vehicles equipped with manual steering
gear, check for seal leakage.) Inspect final drive axle output shaft seals for
leaking.
Brake systems inspection For convenience the following should be
done when wheels are removed for rotation: Inspect lines and hoses for
proper hookup, binding, leaks, cracks, chafing, etc. Inspect disc brake pads
for wear and rotors for surface condition. Also inspect drum brake linings for
wear and cracks. Inspect other brake parts, including drums, wheel cylinders,
parking brake, etc. at the same time. Check parking brake adjustment. In
spect brakes more often if driving habits or conditions result in frequent
braking.
Exhaust system inspection * Inspect complete system including cata
lytic converter. Inspect body near the exhaust system. Look for broken, dam
aged, missing or out-of-position parts, as well as, open seams, holes, loose
connections or other conditions which could cause a heat buildup in the floor
pan or could let exhaust fumes seep into the passenger compartments.
T hrottle linkage inspection Inspect for interference, binding, damaged
or missing parts. Replace parts as needed.
Engine drive belts inspection Inspect all belts for cracks, fraying, wear
and proper tension. Adjust or replace as needed.
Axle rear/front, transfer case (four-wheel drive) Refer to Section 0 in
your Owners Manual to determine the GVWR for your vehicle. Check fluid
level and add if needed.
Locking differential - under 8600-lbs. GVWR Drain fluid at first oil
change and refill. Check fluid level and add as needed at subsequent
oil changes. In dusty areas, or trailer towing applications drain fluid at
every oil change and refill, f
Locking differential - over 8600-lbs. GVWR Drain fluid at first oil
change and refill. Change fluid at every other oil change and check and
add fluid at subsequent oil changes. In dusty areas, or trailer towing
applications, drain fluid at every oil change and refill as specified, f
20
Standard d ifferential - under 8600-lbs. GVWR Check fluid level

and add as needed at every oil change. In dusty areas, or trailer towing
applications, drain fluid every oil change and refill, t
Standard d ifferential - over 8600-lbs. GVWR Drain fluid every
fourth oil change and refill. Check fluid level and add as needed at
every oil change. In dusty areas, or trailer towing applications, drain
fluid at every oil change and refill, f
Transfer case (four-wheel drive) Every 12 months or at oil change
intervals, check front axle and transfer case and add lubricant when
necessary. Lubricate propeller shaft slip joint, constant velocity univer
sal joint and steering linkage. Oil the control lever pivot point and all
exposed control linkage. Check vent hose at transfer case for kinks and
proper installation. More frequent lubrication may be required on
heavy-duty off-road use. t
AT LEAST ONCE A YEAR

Starter safety sw itch operation
CAUTION: Before perform ing the follow ing safety sw itch

check, be sure to have enough room around the vehicle.
Then, firm ly apply both the parking brake (see your O wners
Manual fo r procedure) and the regular brakes. Do not use
the accelerator pedal. If the engine starts, be ready to turn
o ff the ig nition prom ptly. Take these precautions because
the vehicle could move w ith o ut warning and possibly cause
personal injury or property damage.
On automatic transmission vehicles, try to start the engine in each gear.
The starter should crank only in Park or Neutral.
On manual transmission vehicles place the shift lever in Neutral, push
the clutch halfway and try to start. The starter should crank only when
the clutch is fully depressed.
Steering colum n lock operation While parked, try to turn key to Lock
position in each gear range. The key should turn to Lock only when gear is
in Park on automatic or Reverse on manual transmission. On vehicles
with a key release lever, try to turn the key to Lock without depressing the
lever. The key should turn to Lock only with the key lever depressed. On all
vehicles, the key should come out only in Lock.
21
Parking brake and transm ission Park mechanism operation
CAUTION: Before checking the holding ability of the parking

brake and autom atic transm ission Park mechanism, park
on a fairly steep hill with enough room fo r movement in the
dow nhill direction; to reduce the risk of personal injury or
property damage, be prepared to apply the regular brakes
prom ptly if the vehicle begins to move.
To check the parking brake with the engine running and transmission shift
lever in Neutral, slowly remove foot pressure from the regular brake
pedal until the vehicle is held by only the parking brake.
To check the automatic transmission Park mechanism holding ability,
release all brakes after shifting the transmission to Park.
Lap and shoulder belts condition and operation Inspect belt system,
including: webbing, buckles, latch plates, retractors, guide loops and an
chors. Have any defects repaired immediately.
Movable head restraint operation On vehicles with movable head re
straints, make sure restraints stay in the desired position. Refer to Section 1
in your Owners Manual for adjustment instructions in your Owners Manual.
Seatback latch and recliner operation on vehicles equipped w ith recliner seat Be sure seatbacks latch on those vehicles with folding seats
using mechanical latches. Make sure the recliner is holding by pushing and
pulling on the top of the seatback while it is reclined. Refer to Section 1 of
your Owners Manual for seat operating information.
Spare tire and jack storage Be alert to rattles in the rear of the vehicle.
Make sure the spare tire, all jacking equipment, and any covers or doors are
securely stowed at all times. Oil the jack ratchet or screw mechanism after
each use.
Underbody flushing At least every spring, flush the underbody with
plain water to remove any corrosive materials used for ice and snow removal,
and dust control. Take care to thoroughly clean any areas where mud and
other debris can collect. Sediment packed in closed areas of the vehicle
should be loosened before being flushed.
Engine cooling system service * t Inspect coolant and freeze protec
tion. If dirty or rusty, drain, flush and refill with new coolant. Keep coolant at
the proper mixture as specified in Section 5 of your Owners Manual. This
provides proper freeze protection, corrosion inhibitor level and engine operat
ing temperature. Inspect hoses and replace if cracked, swollen or deteriora
ted. Tighten hose clamps. Clean outside of radiator and air conditioning
condenser. Wash radiator filler cap and neck. To help ensure proper opera
22
tion, a pressure test of both the cooling system and cap is also recom
m ended. See m ainten an ce sch ed ule ch arts in Section A for the
recommended coolant change interval.
Body Lubrication Service Lubricate all body door hinges including the
tailgate (if equipped) also lubricate the body hood, fuel door and rear com
partment hinges and latches including interior glove box and console doors,
and any folding seat hardware.
23
SECTION E
RECOMMENDED FLUIDS & LUBRICANTS
NOTE: Fluids and lubricants identified below by name, part number or speci
fication may be obtained from your GM Truck Dealer.
USAGE
FLUID/LUBRICANT
Engine Oil
GM Goodwrench Motor Oil or equivalent for API

Service SF/CC or SF/CD of the recommended vis
cosity
Engine Coolant
Mixture of water and a good quality ethylene glycol

base antifreeze conforming to GM-1825-M GM Part
No. 1052753
Brake and Hydraulic Clutch

Systems
D e lco S up rem e
1052535 or DOT-3
Parking Brake Cables
Chassis grease meeting requirements of GM-6031M GM Part No. 1052497
Power Steering System
GM Power Steering Fluid GM Part No. 1050017 or

equivalent
Manual Steering Gear
GM Lubricant Part No. 1052182 or equivalent
DEXRON II Automatic Transmission Fiuid GM

Part No. 1051855
11
flu id
GM
Part
No.
Manual Transmission:
3-Speed
(RPO M62 and M64)
SAE-80W GL-5 or SAE-80W-90 GL5 gear lubricant

GM Part No. 1052271 (use SAE-80W GL-5 in Can
ada)
4-Speed
(RPO MC9, MF2, and M73)
Dexron II Automatic Transmission Fluid GM Part

No. 1051855
4-Speed (RPO M20)
SAE-80W GL-5 or SAE-80W-90 GL5 gear lubricant

GM part No. 1052271 (use SAE-80W GL-5 in Can
ada)
4-S p ee d O ve rd rive (RPO

MY6)
Dexron II Automatic Transmission Fluid GM Part

No. 1051855
4-Speed W ithou t C reeper Manual Transmission Fluid GM Part No. 1052931.

Gear (RPO MCO)
5-Speed (RPO ML2, ML3 and Dexron II Automatic Transmission Fluid GM Part
MH3)
No. 1051855
5-Speed (RPO MG5)
Manual Transmission Fluid GM Part No. 1052931
Differential:
Standard - Front and Rear SAE-80W-90 GL-5 gear lubricant GM Part No.
Axle
1052271 (use SAE-80W GL-5 in Canada).
Locking
SAE-80W-90 gear lubricant GM Part No. 1052271

(use SAE-80W GL-5 in Canada)
RECOMMENDED FLUIDS & LUBRICANTS

(Contd.)
Transfer Case
Dexron II Automatic Transmission

Fluid GM Part No. 1051855
Manual Transmission Shift Linkage, Col

umn Shift, Propeller Shaft Slip Joint
Chassis grease meeting requirements of

GM-6031-M GM Part No. 1052497
Clutch Linkage (Manual Transmission

without hydraulic clutches only)
a. Pivot points
b. Pushrod to clutch fork joint, and
shaft pressure fitting
Hood Latch Assembly
a. Pivots and spring anchor
b. Release pawl
a. Engine oil
b. Chassis grease meeting
requirements of GM-6031-M GM
No. 1051344
a. Engine oil or GM Part No. 1050109
b. Chassis Grease m eeting require
ments of GM-6031-M GM Part No.
1052497
Front Wheel Bearings
GM Lubricant Part No. 1051344
Constant Velocity Universal Joint
GM Lubricant Part No. 1052497.
Automatic Transmission Shift Linkage,

Floor Shift Linkage, Hood and Door
Hinges, Body Door Hinge Pins, Tailgate
Hinge and Linkage, Folding Seat, Fuel
Door Hinge
Engine oil
Key Lock Cylinders
Light oil (10W-30) or Dri-Slide lubricant

GM Part No. 1052948, or general-pur
pose silicone lubricant, GM Part No.
1052276.
Chassis Lubrication
Chassis grease meeting requirements of

GM-6031M, GM Part No. 1052497.
Windshield Washer Solvent
GM Optikleen washer solvent GM Part

No. 1051515 or equivalent.
Weatherstrip
Silicone grease GM Part No. 1052863 or

equivalent.
NOTE: Silicone lubricants should not be used on lock cylinders with plastic
caps.
1A-1
SECTION 1
HEATING AND AIR CONDITIONING

CONTENTS
SUBJECT
PAGE
H e a tin g ................................................................................................................................................................................................1A-1
A ir C o n d itio n in g ................................................................................................................................................................................1B-1
SECTION 1A
HEATING
CONTENTS
SUBJECT
PAGE
R/V And G Series Heaters Description................................................................................................................. 1A - 2

Blower And Air Inlet Assembly................................................................................................................................1A- 2
Heater Distributor Assembly................................................................................................. ...................................1A- 2
Functional T e s t............................................... .............................................................................................................1A - 2
Insufficient Heat Diagnosis.......................................................................................................................................... 1A- 5
Heater Circuit Diagnosis.............................................................................................................................................. 1A- 8
Diagnosis of the Heater S y s te m ............................................. .................................................................................. 1A- 9
R/V Series Heater On-Vehicle S e rvice ................................................................................................................. 1A-10
Blower Motor Replacement...................................................................................................................................... 1A-10
Heater Hose R outing................................................................................................................................................ 1A-10
Heater Distributor Case and Core Replacement................................................................................................... 1A-10
Control Assembly Replacement................................................................ ............................................................. 1A-11
Control Cable Replacem ent.................................................................................................................................... 1A-12
Cable Adjustment.......................................................................................................................................................1A-14
Blower Switch Replacement......................................................................................... ....................................... 1A-14
Resistor Replacement.............................................................................................................................................. 1A -1 4
Vent Replacement.....................................................................................................................................................1A-14
R/V Series Auxiliary H e a te r........................................................................................................................................ 1A-15
Description.................................................................................................................................................................1A-15
D iagnosis....................................................................................................................................................................... 1A-17
On-Vehicle S e rv ice .................................................................................................................................................... .1A-17
Blower Motor Replacement...................................................................................................................................... 1A -1 7
Heater Core Replacement...................................................................... ...................... ....................................... 1A -1 7
Resistor Replacement............................................................. . .............................................................................. 1A -1 7
Auxiliary Blower Switch Replacement................................................................................................................... 1A-17
Coolant-Control Valve Replacem ent......................................................................................................................1A-17
G Series Heater On-Vehicle S ervice............................................. ........................................................................1A-18
Blower Motor Replacement.......... ........................................................................................................................... 1A-18
Heater Hose R outing............................................................................................... ............................................. 1A-18
Heater Distributor Case and Core Replacement................................................................................................... 1 A - 1 9
Distributor And Defroster Duct Replacement.............................................................................. ........................ 1A-21
Control Assembly and/or Blower Switch Replacement.......................................................................................1A-22
Control Cable Replacement .................................................................................................................................... 1A-22
Cable Adjustment...................................................................................................................................................... 1A-22
Resistor Replacement.............................................................................................................................................. 1A-22
Vent Replacement.................................................................................................................................................... 1A-22
G Series Auxiliary H eater............................................................................................................................................ 1A- 23
Description.................................................................................................................................................................1A-23
D iagnosis.......................................................................................................................................................................1A-25
On-Vehicle S e rvice ........ ............................................................................................................................................. 1A-25
Blower Motor Replacement......................................................................................................................................1A-25
Heater Core Replacement........................................................................................................................................ 1A-26
Coolant-Control Valve Replacem ent..................................................................................................................... 1A-26
Resistor Replacement.............................................................................................................................................. 1A-26
S pecifications...............................................................................................................................................................IA - 2 6
1A-2 HEATING
R/V AND G SERIES HEATERS-DESCRIPTION

Heating com ponents are attached to the right side of
the cowl. The blower and air inlet assembly and water
hoses are located on the forward side of the cowl panel
while the heater core and distributor duct are on the pas
senger side.
The heater system is an air-mix type system in which
outside air is heated and then mixed in varying amounts
with cooler outside air to attain the desired air tempera
ture. The system consists of (1) a blower and air inlet as
sembly, (2) a heater distributor assembly and (3) a heater
control assembly.
BLOWER AND AIR INLET

ASSEMBLY
The blower and air inlet assembly draws outside air
through the outside air inlet grille located forward of the
windshield reveal m olding and channels the air into the
heater distributor assembly. The operation of the blower
motor is controlled by the fan switch on the heater control.
The motor is connected in series with the fan switch and
the blower resistor assembly.
HEATER DISTRIBUTOR
ASSEMBLY
The heater distributor assem bly houses the heater core
and the doors necessary to control mixing and channeling
of the air. Since the unit has no water valve, water
circulation keeps the core hot at all times. That portion of
the air passing through the core receives m axim um heat
from the core. A ir entering the distributor assembly is
channeled as follows:
Air entering the distributor can be directed out the
purge door opening on the right end of the distributor
assembly by the temperature door. If the temperature
door is closed, air is directed through and/or around the
heater core by the temperature door. Air is then directed
into the passenger com partm ent through the heater (floor)
outlets and/or the defroster (dash) outlets by the defroster
door. The temperature of the outlet air is dependent on
the ratio of heated to unheated air (controlled by the
temperature door).
FUNCTIONAL TEST
Perform this test as one operation:
1. For R/V Series, refer to figure 1.
2. For G Series, refer to figure 2.
HEATING 1A-3
FUNCTIONAL TEST-R-V SERIES

P e rform th is te s t as o ne o p e ra tio n by o ne in s p e c to r in o n e s ta tio n ro ll-o ff te s t.
HI
OFF
HEATER
J M j
$
*
HOT
: o ld
V
OFF
________________________ 1
CONTROL SETTINGS
SYSTEM RESPONSE
MODE
TEMPERATURE
FAN
BLOWER
HEATER
DEFROSTER
SEE
STEP
LEVER
LEVER
SWITCH
SPEED
OUTLET
OUTLETS
REMARKS
OFF
COLD
OFF
OFF
NO AIR FLOW
NO AIR FLOW
OFF
COLD
OFF TO HI
OFF TO HI
NO AIR FLOW
NO AIR FLOW
HEAT
HOT
HI
HIGH
AIR FLOW
MIN AIR FLOW
B, C
DEFROST
HOT
HI
HIGH
MIN AIR FLOW
AIR FLOW
R EM AR KS:
A. A ch a n g e in b lo w e r speed m u s t o c c u r fro m Low, M e d iu m to H igh .
B. D e te n t e n g a g e m e n t m u s t be fe lt in each m ode.
C. C h e c k th e te m p e ra tu re lever fo r e ffo rt and travel (C old to H ot).
Figure 1Functional Test-R/V Trucks
F-02037
1A-4 HEATING
Heater Functional TestG Series

P erform th is te s t as one o p e ra tio n by o ne in s p e c to r in o n e s ta tio n o ff ro ll te s t.
SYSTEM RESPONSE
CONTROL SETTINGS
MODE
CONTROL
TEMPERATURE
CONTROL
FAN
SWITCH
HTR
COLD (BLUE)
HTR
COLD
HTR
DEFROST
STEP
BLOWER
SPEED
HEATER
OUTLET
OFF
OFF
NO AIR FLOW
NO AIR FLOW
OFF TO HI
OFF TO HI
AIR FLOW
MIN AIR FLOW
HOT (RED)
HI
HI
AIR FLOW
MIN AIR FLOW
HOT
HI
HI
MIN AIR FLOW
AIR FLOW
B, C
B
DEFROSTER
OUTLETS
SEE
REMARKS
REMARKS:
A. A n o tic e a b le b lo w e r sp ee d m u s t o c c u r fro m low, m e d iu m to h ig h.
B. The e n g a g e m e n t d e te n t m u s t be fe lt in each m ode.
C. C h e ck th e te m p e ra tu re lever fo r e ffo rt and fu ll travel (co ld to hot).
Hot Air Check

W ith th e m o d e lever in d e fro s t
th e te m p e ra tu re lever in h ot, th e fan s w itc h in HI, th e
te m p e ra tu re fro m th e d e fro s te r o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e v e h ic le .
F-02134
Figure 2Functional Test-G Vans
HEATING 1A-5
F-02135
Figure 3Insufficient Heat Diagnosis
1A-6 HEATING
CHART A
F-02136
HEATING 1A-7
CHART B
F-02137
1A-8 HEATING
HEATER CIRCUIT DIAGNOSIS

BLOWER MOTOR INOPERATIVE
I
CHECK THE FUSE IN THE FUSE PANEL.I
1
FUSE OK
------1.......
TEST WITH THE IGNITION SWITCH IN RUN POSITION, THE
BLOWER SPEED SWITCH ON AND THE LEVER I J THE HEAT POSITION.
FUSE BLOWN
X
WITH THE IGNITION SWITCH IN THE

RUN POSITION AND THE BLOWER
SPEED SWITCH ON USE A METER TO
LOCATE A SHORT IN ONE OF THE FOL
LOWING WIRES:
1. FROM THE FUSE PANEL TO THE
BLOWER SPEED SWITCH.
2. FROM THE BLOWER SPEED SWITCH
TO THE HEATER RESISTOR.
3. FROM THE HEATER RESISTOR TO
THE BLOWER.
NOTE: A SHORT IN THE CIRCUIT MAY
BE INTERMITTENT. IF THE METEP DOES
NOT INDICATE A SHORT CIRCUIT, MOVE
THE HEARNESS AROUND AS MUCH AS
POSSIBLE TO RE-CREATE A SHORT CIR
CUIT. WATCH AND LISTEN FOR
ARCING.
I
CHECK THE BLOWER MOTOR GROUND.
X
POOR OR NO GROUND
GROUND OK
...... ..... i .............:

CHECK THE MOTOR CONNECTOR WITH
A 12-VOLT TEST LIGHT.
REPAIR THE GROUND.
1
LAMP DOES NOT LIGHT
LAMP LIGHTS
REPLACE THE MOTOR.
CHECKTHE BLOWER FEED WIRE IN

THE CONNECTOR ON THE RESIS
TOR WITH A 12-VOLT TEST LIGHT.
LAMP DOES NOT LIGHT
LAMP LIGHTS
USE A 12-VOLT TEST LIGHT AND CHECK

THE FEED TERMINAL (BROWN) ON THE
BLOWER SPEED SWITCH.
1.
LAMP LIGHTS
LAMP DOES NOT LIGHT

T
REPAIR THE OPEN IN THE BROWN WIRE FROM THE

BLOWER SPEED SWITCH TO THE FUSE PANEL.
REPLACE THE SWITCH.
..........I ........
REPAIR THE OPEN IN
THE FEED WIRE FROM
THE RESISTOR TO THE
BLOWER MOTOR.
BLOWER MOTOR INOPERATIVE

(CERTAIN SPEEDS)
~~
T
DISCONNECT THE RESISTOR CONNECTOR, CONNECT ONE LEAD OF A SELF POWERED TEST LIGHT TO ANY ONE
TERMINAL AND USE THE OTHER LEAD TO PROBE EACH OF THE OTHER TWO TERMINALS.
I
X
TEST LIGHT DOES NOT LIGHT
ON ALL THE TERMINALS.
I
TEST LIGHT LIGHTS ON ALL THE TERMINALS

I
WITH THE IGNITION OFF, DISCONNECT THE 3 WIRE CONNECTOR FROM RESIS
TOR. CONNECT A JUMPER LEAD FROM THE BATTERY POSITIVE TERMINAL
TO ANY WIRE TERMINAL IN CONNECTOR. USE A 12-VOLT TEST LIGHT TO
CHECK FOR VOLTAGE AT THE CORRESPONDING WIRE ON THE BLOWER
SPEED SWITCH. REPEAT THE SAME TEST ON THE OTHER WIRES.
REPLACE THE RESISTOR.
X
LAMP LIGHTS ON ALL THREE WIRES
.............................
REPLACE THE BLOWER SPEED SWITCH.
1
LAMP LIGHTS ON ALL THREE WIRES
LAMP DOES NOT LIGHT ON ALL THREE WIRES
I
REPAIR THE OPEN IN AFFECTED WIRE.
Figure 6Heater Circuit Diagnosis
F-02038
HEATING 1A-9
DIAGNOSIS OF THE HEATER SYSTEM

PROBLEM
POSSIBLE CAUSE
Temperature Of
Heater Air At The
Outlets Is Too Low
To Heat Up Passenger
Compartment
Refer to Insufficient Heat Diagnosis.
Temperature Of
Heater Air At The
Outlets Is Adequate
But The Vehicle Will
Not Build Up
Sufficient Heat
Inadequate Defrosting
Action
1. Floor side kick pad ventilators partially

open.
2. Leaking grommets in dash.
3. Leaking welded seams along the rocker
panel and windshield.
4. Leaks through the access holes and
screw holes.
5. Leaking rubber molding around the door
and windows.
6. Leaks between the sealing edge of blo
wer and the air inlet assem bly and cowl,
and between the sealing edge of the
heater distributor assembly and cowl.
1. Check that the DEFROST lever comple
tely opens the defroster door in the DEF
position.
2. Insure that the temperature and air doors
open fully.
3. Look for obstructions in the defroster
ducts.
4. Check for air leak in the ducting between
the defroster outlet on heater assembly
and the defroster duct under the instru
ment panel.
5. Check the position of the bottom of the
nozzle to the heater locating tab.
6. Check the position of the defroster noz
zle openings relative to instrum ent panel
openings. M ounting tabs provide positive
position if properly installed.
Inadequate Circulation
Of Heated Air
Through The Vehicle
1. Check the heater outlet for correct instal

lation.
2. Inspect the floor carpet to insure that the
carpet lies flat under the front seat and
does not obstruct air flow. Also inspect
around the outlet ducts to insure that the
carpet is well fastened to floor to prevent
cupping of the air flow.
Erratic Heater
Operation
1. Check the coolant level.

2. Check for kinked heater hoses.
3. Check the operation of all bowden ca
bles and doors.
4. Sedim ent in the heater lines and radiator
causing the engine therm ostat to stick
open.
5. Partially plugged heater core.
CORRECTION
Refer to Insufficient Heat D iagnosis.
1. Check and adjust.

2. Reseal or replace.
3. Clean and rewash.
1. Adjust if necessary.
2. Adjust.
3. Remove any obstructions.
4. Seal area as necessary.
5. Adjust.
6. Adjust the defroster nozzle openings.
1. Remove and install.

2. Correct as necessary.
1. Fill to the proper level.

2. Relieve kinks or replace hoses.
3. Adjust as necessary.
4. Flush the system and clean or replace
therm ostat as necessary.
5. Backflush core as necessary.
1A-10 HEATING
DIAGNOSIS OF THE HEATER SYSTEM (CONT.)

PROBLEM
Hard Operating Or
Broken Controls
POSSIBLE CAUSE
CORRECTION
1. Check for loose cable tab screws or misadjusted cables.

2. Check for sticking heater system door(s).
1. Correct as required.
2. Lubricate as required using a silicone
spray.
R/V SERIES HEATERON-VEHICLE SERVICE

BLOWER MOTOR
REPLACEMENT
Remove or Disconnect (Figures 7 and 8)
1 Draw hoses tight to prevent sagging or rubbing against

other components. Route hoses through all clamps as
installed originally.
1. Battery ground cable.
HEATER DISTRIBUTOR CASE

AND CORE REPLACEMENT
2. Blower motor wiring harness (3) (figure 7):

3. Motor (13) and fan (15) assembly (figure 8).
Five mounting screws.
Gently pry on the blower flange if the sealer acts
like an adhesive.
Shaft nut (16).
Fan (15) from the motor (13).
Remove or Disconnect (Figures 8 through 14)

Battery ground cable.
Heater hoses (40 and 41) at the core tubes (20) (figures
8, 9, 10 and 11).
Install or Connect (Figures 7 and 8)
Drain the engine coolant into a clean pan.

Plug the core tubes to prevent spillage.
Screws (31) and nuts (24) from the studs (6) that
project into the engine compartment (figures 8 and 12).
Instrument panel compartment.
Defroster (51) and temperature cables (52) (figure 13).
Floor outlet (37).
Screw (12) that holds the defroster duct to the heater
distributor (figure 14).
Heater distributor from the dash panel.

Locate the open end of the wheel away from the
blower motor.
Shaft nut (16).
Motor (13) and fan (15) assembly to the case (14).
New bead of sealer to the mounting flange.
Blower motor wiring harness.
Battery ground wire.
Test the motor (13).
HEATER HOSES ROUTING

Heater hoses are routed from the therm ostat housing or
in le t m a n ifo ld and w a te r pum p (ra d ia to r on som e
automatic transm ission vehicles) to the core inlet and
o utlet pipes. Hoses are attached at each end with
screw-type clamps. (Refer to figures 9, 10 and 11).
REPLACEMENT
W hen replacing heater hoses, m aintain a 13 mm
(1/2-inch) m inimum clearance between the hose clip and
the upper control arm, a 38 mm (11/2-inch) minimum
clearance between the hoses and the propshaft, and a 32
mm (11/4-inch) m inimum clearance between the auxiliary
heater core lines and the exhaust pipe.
The heater core can be dam aged near the tube
attachm ent seams if force is applied on them. If the
heater hoses do not come off, cut the hoses forward of
the core tubes. Cut the hose on core tubes to remove.
Pull the assembly rearward to reach the wiring

harness.
9. Wiring harness.
Heater case (24).
10.
11. Core retaining clamps (18 and 19).
0
12.
Core (20).
Install or Connect (Figures 8 through 14)
1. Core (20) to the case (24).

2. Core retaining clamps (18 and 19).
3. Heater case (24) to the vehicle.
4. Screws (31) and nuts to the studs (6).
5. Wiring harness.
6. Floor outlet (37).
7. Defroster (51) and temperature cables (52).
8. Instrument panel compartment.

9. Heater hoses (40 and 41) to the core tubes (20).
11. Coolant to the radiator.
HEATING 1A-11
7.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
S crew
C o n n e c to r
S crew
M o to r
C ase
Fan
N ut
B o lt
C la m p
C la m p
C ore
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
S h a ft
Valve
Valve
C ase
S h a ft
S h rou d
Plate
B o lt
E lb ow
Tube
'E -* 25
F-02218
Figure 8Blower Motor Assembly-Component View-R/V
CONTROL ASSEMBLY
REPLACEMENT
1.
2.
3.
4.
5.
Install or Connect (Figures 13)

If a new unit is being installed, transfer the blower
switch to the new unit.
Remove o r Disconnect (Figure 13)
1. Assembly through the opening above the control.

Instrument panel bezel.
Defroster (51) and temperature cables (52).
Blower switch wiring harness.
Assembly through the opening above the control.
2. Blower switch wiring harness.

4. Instrument panel bezel.
Figure 9Heater Hose Routing-4.3L, 5.0L and 5.7L Engines
1A-12 HEATING
40. H ose O u tle t

41. H ose In le t
42. R a d ia to r
B-08618
F igure 10 H eater Hose R o u tin g -6 .2 L Engine
Figure 11 H eater Hose R o u tin g -7 .4 L Engine
CONTROL CABLE
REPLACEMENT
|* + [ Remove or Disconnect (Figure 13)
Control assembly from the instrument panel.
Cable retainers (53) and tab attaching screws (54).
Pull the control out from the instrument panel for
access.
6. Cable retainers (53) and tab attaching screws (54) at
the heater case.
7. Cable from the retaining clip (58).
8. Cable (50 or 51).

1. Cable (51 or 52).
HEATING 1A-13
F igure 13 C o n tro l A s se m b ly and C ables
1.
45.
46.
47.
48.
49.
C ase
G rille
N ozzle A s s e m b ly
In s tru m e n t Panel
O u tle t
D e fro s t D u c t
B-08617
Figure 14Floor and Defroster Vents
1A-14 HEATING
50. H e a te r/D e fro s te r C o n tro l A s s e m b ly

55. In s tru m e n t Panel W irin g H a rn e ss
56. B lo w e r S w itc h
B-09811
Figure 15Blower Switch

Im portant
Do not kink the cable. Route the cable as
removed. Check the adjustment.
Cable to the retaining clip (58) at the heater case (24).
Cable retainers (53) and the tab screws at the heater
case.
Cable (51 or 52) to the control assembly (50).
6. Cable retainers (53) and tab screws (54).
7. Control assembly (50) to the instrument panel.
4. Control assembly (50) (figure 15).

Pull the control out from the instrument panel.
5. Blower switch wiring harness.
6. Switch (56).
|-n-| Install or Connect (Figure 15)

1.
2.
3.
4.
5.
CABLE ADJUSTMENT
Remove o r Disconnect (Figure 13)
1.
2.
3.
4.

Retainer (53).
Screw (54) from cable tab (57).
Cable (51 or 52) from the heater case (24).
RESISTOR REPLACEMENT
|+ + | Remove or Disconnect (Figures 7 and 16)
1.
2.
3.
4.
Adjust
Hold the cable with a pair of pliers and rotate the
mounting tab (57) to lengthen or shorten the
cable.
NOTICE: Do not pinch the cable.
-H - Install or Connect (Figure 13)

Cable (51 or 52) to the heater case (24).
Tab (57) to the clip (58).
Screw (54).
BLOWER SWITCH
REPLACEMENT
Remove or Disconnect (Figure 15)
3. Control assembly (50) mounting screws.
Switch (56) to the control assembly (50).

Wiring harness to the blower switch (56).
Control assembly (50) to the instrument panel.

Connector (4) (figure 16).
Screws.
Resistor (60).
Install or Connect
1.
2.
3.
4.
Resistor (60).
Screws.
Connector (4).
VENT REPLACEMENT
Right and left vents are installed in the kick panels
u nd er th e in s tru m e n t p an el. R eplace the vents by
removing the attaching screws (figure 17).
HEATING 1A-15
65. Bezel
66. Valve A s s e m b ly
67. In s tru m e n t Panel G a rn ish
68 . K ic k p a n e l
69. C o n tro l C able
Figure 17Vent Assembly
R/V SERIES AUXILIARY HEATER

DESCRIPTION
An auxiliary heater provides additional heating capacity
for the rear of the Suburban model.
T his unit operates in d ep en d en tly of the standard
heater, and is regulated through its own controls at the
instrum ent panel.
This system consists of a separate core and fan unit

mounted in the rear of the vehicle.
Heater hoses extend from the unit to the front of the
vehicle where they are connected to the standard heater
hoses with tees. An on-off vacuum operated valve is
installed in the heater core inlet line in the engine
compartm ent. This valve cuts off coolant flow to the
auxiliary core during warm weather and elim inates radiant
heat (figure 18).
Two control methods are used:
COOLANT-CONTROL VALVE
When heat is desired, and the blower switch is any
position except off, a vacuum operated valve controlled by
the switch, opens the coolant line to perm it hot coolant
circulation through the heater core. In the OFF position
the valve is closed to prevent unwanted heat.
BLOWER SWITCH
The th re e-sp ee d blow er sw itch is loca te d in the
instrum ent panel to the right of the steering column.
Figure 7Blower Motor Assembly Wiring R/V
1A-16 HEATING
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
U p p e r C ase
Seal
C ore
L o w e r C ase
S cre w
Fan
S u p p o rt
G ro m m e t
W a sh e r
S cre w
M o to r
C la m p
S tu d
R e s is to r
Seal
N ut
H a rn e ss
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
C la m p
A u x ilia ry H e a te r In le t R ear H ose
A u x ilia ry H e a te r O u tle t Rear
C lip
S cre w
W a te r H e a te r O u tle t H ose
W a te r H e a te r In le t H ose
S crew
Valve
H a rn e s s
S crew
A u x ilia ry H e a te r S w itc h (S in g le F u n c tio n ) Bezel
A u x ilia ry H e a te r C o n tro l S w itc h
S crew
A u x ilia ry H e a te r/R e ar A ir C o n d itio n in g
C o n tro l S w itc h (Dual F u n c tio n )

107. C o n n e c to r
108. V a cuu m Line
F-02222
Figure 18Auxiliary Heater-Suburban
HEATING 1A-17
DIAGNOSIS
To diagnose the heater system, refer to Insufficient Heat Diagnosis, Heater C ircuit Diagnosis, and Diagnosis of
the Heater System .
ON-VEHICLE SERVICE
Install or Connect (Figure 18)
BLOWER MOTOR REPLACEMENT

4- +
1.
2.
3.
4.
5.
0
1.
2.
3.
4.
5.

Blower motor wiring harness (91).
Clamp (86).
Screws (84) and washer (83).
Motor (85).

Motor (85).
Screws (84) and washers (83).
Clamp (86).
Blower motor wiring harness (91).
HEATER CORE REPLACEMENT


Coolant from the radiator.
Hoses (93 and 94) from the core (77).
Wiring harness (91).
Clamp (86).
Motor (85), support (81) and fan (80) as an assembly.
Upper case (75).
Seal (76).
Core (77).
0
1.
2.
3.
4.
5.
Core (77) to lower case (78).

Seal (76).
Upper case (75).
Motor (85), support (81) and fan (80).
Clamp (86).
Hoses (93 and 94) to the core (77).
Coolant to the radiator.

Screws.
Resistor (88).
Resistor (88).
Screws.
AUXILIARY BLOWER
SWITCH REPLACEMENT
Wiring harness (107) at the switch (104).
Screws (102).
Bezel (103).
Switch (104).

1.
2.
3.
4.
5.
Switch (104) to the bezel (103).

Bezel (103) to the instrument panel.
Screw (102).
Wiring harness (107) to the switch (104).
REPLACEMENT
The coolant-control valve is mounted to the right front
fender. To diagnose the vacuum system, refer to AIR
CONDITIONING (SEC. 1B).
1.
2.
3.
4.
1.
2.
3.
4.
1.
2.
3.
4.
5.

Clamps (92).
Hoses (93, 94, 97 and 98) from the valve.
Vacuum hose (108).
Valve (100).

Valve (100).
Vacuum hose (108).
Hoses (93, 94, 97 and 98).
Clamps (92).
Leak test.
1A-18 HEATING
G SERIES HEATERON-VEHICLE SERVICE

113
110. N u t
111. Fan A s s e m b ly
112. W a s h e r
113. M o to r
114. Tube
115. F ittin g
116. C ase
117. G a s k e t
118. Pin
119. Valve
120. S h a ft
114
121. H o u s in g
122. C ore
123. S tra p
124. C ase
125. B ra c k e t
126. Valve
127. S h a ft A s s e m b ly
128. D u c t
B-09761
Figure 19Blower Motor Assembly Component View

1.
2.
3.
4.
5.
6.

Coolant overflow hose from the recovery bottle.
Fasteners.
Bottle from the vehicle.
Blower motor and wiring harness.
Motor (113) and fan (111) assembly (figure 19).
Gently pry on the blower flange if the sealer acts
like an adhesive.
7. Nut (110).
8. Fan (111) from the motor (113).

1. Fan (111) to the motor (113).
Locate the open end of the wheel away from the
blower motor.
2. Nut (110).
3. Motor (113) and fan (111) assembly.
Bead of sealer to the mounting flange.
4. Blower motor wiring harness.
5. Coolant bottle to the vehicle.
6. Fasteners.
7. Coolant hose.
9. Test the motor.
HEATER HOSE ROUTING

Heater hoses are routed from the therm ostat housing or
in le t m a n ifo ld and w a te r p u m p (ra d ia to r on som e
automatic transm ission vehicles) to the core inlet and
outlet pipes. Hoses are a ttached at each end with
screw-type clamps. (Refer to figures 20, 21 and 22).
REPLACEMENT
W hen replacing heater hoses, m aintain a 13 mm
(1/2-inch) m inimum clearance between the hose clip and
the upper control arm, a 38 mm (11/2-inch) minimum
clearance between the hoses and the propshaft, and a 32
mm (11/4-inch) m inimum clearance between the auxiliary
heater core lines and the exhaust pipe.
The heater core can be dam aged near the tube
attachm ent seams if force is applied on them . If the
heater hoses do not come off, cut the hoses forward of
the core tubes. Cut the hose on the core tubes to remove.
Im portant
Draw hoses tight to prevent sagging or rubbing against
other components. Route hoses through all clamps as
installed originally.
HEATING 1A-19
Figure 20Heater Hose Routing-4.3L, 5.0L and 7.4L Engines
HEATER DISTRIBUTOR CASE

AND CORE REPLACEMENT
+ + Remove or Disconnect (Figures 19 through 24)
Coolant recovery tank.
Heater core hoses (140 and 141) (figures 20, 21 and
22).
4.
5.
140. H ose O u tle t

141. H ose In le t
142. R a d ia to r
140
8.
9.
10.
B-08352
11.
Figure 22Heater Hose Routing-7.4L Engine
12.
13.
Place a clean pan under the vehicle to catch any

coolant spillage.
Plug the hoses.
Allow coolant in the core to drain into the pan.
Heater distributor duct (134) (figure 23).
Remove the screws that hold the distributor duct
to the distributor case and the distributor duct to
the engine cover.
Engine housing cover.
Refer to INTERIOR TRIM (SEC. 10A4).
Remove the screws at the windshield, all lower
screws and the right instrument panel support
bracket at the door pillar and the engine housing.
Instrument panel.
Lower the steering column.
Refer to STEERING COLUMN (SEC. 3B4).
R aise and s u p p o rt the rig h t side of the
instrument panel.
Defroster duct (130) to distributor case (124) attaching
screws.
Distributor to heater case (2) screws.
Temperature door cable (145) (figure 24).
Fold the cable back for access.
Heater case (124) and core (122).
Three nuts at the engine compartment side of
the distributor case and one screw on the
passenger side.
Tilt the case assembly rearward at the top while
lifting up until the core tubes clear the dash
openings.
Core retaining straps (123).
Core (122).
1A-20 HEATING
131. Seal
133. L eft-h a n d O u tle t A s s e m b ly
134. D u c t A s s e m b ly
F-00659
Figure 23Distributor Ducts
HEATING 1A-21
F igure 24 C o n tro l A s s e m b ly and C ables

1. Core (122) to the heater case (124).
Apply a bead of sealer between the core and the
case.
DISTRIBUTOR AND DEFROSTER

DUCT REPLACEMENT
|<-+| Remove or Disconnect (Figure 23)
2. Core retaining straps (123).
3. Heater case (124) to the vehicle.
2. Raise the instrument panel at the right side.
Apply a bead of sealer between the heater case

and the opening in the vehicle.
Tilt the case until the core tubes clear the cowl
opening.
4. Temperature cable (145) to the heater case (124).
5. Distributor duct (134) to the heater case (124).
6. Defroster duct (130) to the heater case (124).
7. Instrument panel.
8. Steering column.
9. Engine housing cover.
10. Heater core hoses (100 and 141).
11. Coolant recover tank.
3. Engine cover.
Unsnap the engine cover front latches and
remove the two cover-to-floor pan screws.
4. Distributor duct (134) from the heater case (124).
Pull the center distributor duct to the right.
5. Defroster duct (130).
Screws that hold the defroster duct to the
instrument panel.

1. Defroster duct (130).
2. Distributor duct (134) to the heater case (124).
3. Engine cover.
13. Leak test.
1A-22 HEATING
CONTROL ASSEMBLY AND/OR
BLOWER SWITCH REPLACEMENT
3. Control assembly (147) from the instrument panel.
Pull the control assembly out to reach the
defroster (145) and temperature cables (146).
5. W irin g h arne ss to th e b low er sw itch and the
illumination bulb.
6. Control assembly (147) from the vehicle.
7. Blower switch (56).
1. Blower switch (56) to the control assembly (147).
2. Wiring harness to the blower switch (56) and the
illumination bulb.
3. Defroster (145) and temperature (146) cables.
CONTROL CABLE REPLACEMENT

For additional room, place the transmission shift
lever in low.
Control assembly (147) from the instrument panel.
Cable retainers (148) and tab screws (149).
R aise or lo w e r th e c o n tro l a ss e m b ly as
necessary.
Cable (145 or 146) from the control assembly (147).
Cable retainer (148) and tab screws at the heater case.
-* Install or Connect(Figures 15 and 24)
1. Cable (145 or 146) to the heater assembly (124).
Retaining clip (150) and screw (149).
Retainers (148).
3. Cable (145 or 146) to the control assembly (147).
Retaining clip (150) and screw (149).
Retainer (148).
Figure 25Resistor Replacement

Attach the cable sheath to the heater case (124).
Move the temperature lever to full heat. This will
require force to slide the inner cable clip to its proper
position.
++ Remove or Disconnect (Figure 25)
1.
2.
3.
4.

Wiring harness from the resistor (171) (figure 25).
Screws (173).
Resistor (171).

1.
2.
3.
4.
Resistor (171).
Screws (173).
Wiring harness to the resistor (171).
VENT REPLACEMENT
CABLE ADJUSTMENT
|+ + l Remove or Disconnect (Figure 26)
A djust (Figure 24)
1. Attach the inner cable and sheath to the instrument
pane! control.
2. Move the temperature cable (145) to cold.
3. Attach the loop on the inner cable to the temperature
door (145 on the heater case (124).
1. Screws (204).
2. Valve assembly (202).

1. Valve assembly (202).
2. Screws (204).
HEATING 1A-23
200. Seal
201. O u tle t
202. Valve A s s e m b ly
203. C lip
204. S crew
205. K n ob
206. Rod
207. G u id e
208. O u tle t
209. Seal
210. In le t A s s e m b ly
211. C ove r
F-00657
Figure 26Vent Replacement
G SERIES AUXILIARY HEATER

DESCRIPTION
An auxiliary heater provides additional heating for the
rear area of the vehicle.
It operates independently of the standard heater, and is
regulated through its own control at the instrum ent panel.
This system consists of a separate core fan vent
(figures 27 and 28).
Heater hoses extend from the unit to the front of the
vehicle where they are connected to the standard heater
hoses with tees.
There are two control methods:
An o n-off vacuum -operated, coolant-control valve
in s ta lle d in th e h e a te r c o re in le t in th e e n g in e
com partm ent controls coolant flow to the auxiliary heater
and elim inates radiant heat during warm weather. To
d ia g n o s e th e v a c u u m
s y s te m
re fe r to A IR
BLOWER SWITCH
For heating, the blower switch is placed in any position
except off. The switch opens the coolant-control valve
which permits hot coolant to enter the heater core. In the
OFF position, the valve is closed to prevent unwanted
heat during warm weather.
1A-24 HEATING
164
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
C over
C ore
Seal
Tube
R e s is to r
C ase
W a sh e r
Fan
N ut
P late
S cre w
S creen
W irin g H a rn e ss
S tu d
M o to r
S tra p
T erm in al
S crew
S crew
F-02231
Figure 27Auxiliary Heater Component View
HEATING 1A-25
180
170
185
184
170.
171.
172.
173.
174.
175.
176.
177.
178.
179.
180.
181.
182.
183.
184.
185.
186.
187.
H e a te r A s s e m b ly
Seal
C ia m p
S crew
W a sh e r
cirp
S crew
S tra p
M ate ria l
H ose
H ose
S trap
C lip
Tee
Tee
S crew
H ose
Tee
188. Tank
r
189.
190.
191.
192.
193.
194.
195.
196.
197.
198.
S crew
H ose
N ut
S w itc h
N ut
Label
Knob
H a rn e ss
R e ta in e r
W ire A s s e m b ly
180 179
176
178
B-09753
Figure 28Auxiliary Heater Plumbing Component View
DIAGNOSIS
To diagnose the auxiliary heater, refer to Insufficient Heat Diagnosis, Heater Circuit Diagnosis and Diagnosis of
the Heater System .
ON-VEHICLE SERVICE
- Install or Connect (Figure 28)

1. Fan (157) to the motor (164).
1.
2.
3.
4.
5.
6.
7.
8.
9.
2. Nut (158) to the motor (164) shaft.

Screws (168).
Cover (150).
Wiring harness to the motor (162).
Screws (160).
Motor (164) and fan (157) assembly.
Nut (158) from the motor (164).
Motor (164).
3. Motor (164), fan (157) and nut (158) to the case (155).
Apply a bead of sealer to the motor (164) flange.
4. Screws (160).
5. Wiring harness (162) to the motor (168).
6. Cover (150).
7. Screws (168).
1A-26 HEATING
HEATER CORE REPLACEMENT
COOLANT CONTROL VALVE

REPLACEMENT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Clamps (172) from the coolant hoses (179 and 180).
Coolant hoses (179 and 180) from the core (151).
Studs (163) from the case (155).
Screws (168).
Cover (150).
Wiring harness (162) from the motor (164) and the
resistor (154).
Case (155) and plate (159) from the vehicle.
Screws (160).
Plate (159) from the case (155).
Seal (152).
Core (151).
The coolant-control valve is attached to the right side of

the cowl in the engine compartm ent.

1.
2.
3.
4.
5.
|+<-| Install or Connect (Figure 28)

1.
2.
3.
4.
5.

1.
2:
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Core (151) to the case (155).

Seal (152) to the case (155).
Plate (159) to the case (155).
Screws (160).
Case (155) and plate (159) to the vehicle.
Wiring harness (162) to the motor (164) and the resistor
(154).
Cover (150).
Screws (168).
Coolant hoses (179 and 180) to the case (155).
Clamps (172) to the coolant hoses (179 and 180).
Studs (163) to the case (155).
Leak test.

Coolant hoses.
Vacuum line.
Screws.
Valve (183).
Valve (183).
Screws.
Vacuum line.
Coolant hoses.
Screws (168).
Cover (150).
Wiring harness (162) to the resistor (154).
Resistor (154).
|-<-| Install or Connect (Figure 28)

1.
2.
3.
4.
5.
Resistor (154).
Wiring harness (169) to the ressistor (154).
Cover (155).
Screws (168).
SPECIFICATIONS
HEATER
Volts
Amps.
(Cold)
R/V S eries...........................................................................................
13.5
6.25 Max.
G S e r ie s .............................................................................................
13.5
7.1 Max.
RPM
(Cold)
Blower Motor
2550
2950
2850
3250
Min.
Max.
Min.
Max.
Fuses
R/V S e r ie s ...................................................................................................................................................... 20 Amp.
G S e rie s ...........................................................................................................................................................20 Amp.
AUXILIARY HEATER
Blower Motor.
Volts
Amps.
(Cold)
RPM
(Cold)
13.5
9.6 Max.
2700 Min.
1B-1
SECTION 1B
AIR CONDITIONING
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ...................................................................................................................................................................................... 1 B - 3

CCOT A/C S y s te m .................................................... ...............................................................................................................1 B - 3
Rear In te rio r R oof M ounted S ystem s (S uburban & G S e r ie s ) .................................................................................... 1 B - 3
S ystem C o m p o n e n ts ............................................................................................................................................................... 1 B - 4
P e rio d ic M aintenance and S e r v ic in g ..................................................................................................................................1 B - 4
S ystem O p eratio n RV & G ................................................................................................................................................1 B - 4
F u n ctio n a l T est R/V & G . .................................................................................................................................................. 1 B - 4
R efrige ran t-12 O perating C h a ra c te ris tic s ............................................................................................................................. 1 B - 9
S ystem C om po n en ts and T em p eratu re and P ressure R e la tio n s h ip s .......................................................................1 B - 9
R e frig e ra n t and Oil C a p a c ity ..................................................................................................................................................1 B - 9
H andling R efrigerant-12 .........................................................................................................................................................1 B - 9
H an dling R efrige ran t L ines and F it t in g s ........................................................................................................................... 1 B - 9
M ain ta in in g C hem ical S t a b ility ............................................................................................................................................. 1 B - 9
R e frig e ra n t System D ia g n o s is ..................................................................................................................................................1B-11
In s u ffic ie n t C ooling Q u ick-C h e ck P ro c e d u re ............................................................................................................. 1B-11
S ystem P erform ance T e s t...................................................................................................................................................... 1B-11
T e stin g th e R efrigerant S y s te m ......................................... ................................................................. ............................... 1B-11
Leak T e stin g the R efrige ran t S ystem ................................................................................................................................1 B -13
P ressure Sensing S w it c h ...................................................................................................................................................... 1 B -13
E le ctrica l/V a cu u m T ro u ble D ia g n o s is .................................................................................................................................... 1 B -1 8
O p eratio n al T e s t........................................................................................................................................................................ 1 B -18
V acuum S ystem D ia g n o s is .........................................................................................................................................................1 B -23
R/V and G S e r ie s ......................................................................................................................................................................1 B -23
E vacuating and C harging P ro c e d u re s .................................................................................................................................... 1 B -23
E vacuation and C harging P ro c e d u re s ................................................................................................................................1 B -23
D ischa rg ing , E vacuating, A d d in g Oil, C harging P ro c e d u re s .......................................................................................1 B -23
D ischa rg ing the S y s t e m .........................................................................................................................................................1 B -24
R e frig e ra n t Oil D is trib u tio n .................................................................................................................................................... 1 B -24
E va cua tin g and C harging ...................................................................................................................................................... 1 B -25
Gage C a lib ra tio n ..................................................................................................................................................................1 1 B -26
Vacuum System C h e c k ........................................................................................................................................................... 1 B -26
C harging S tation M e t h o d ...................................................................................................................................................... 1 B -26
D isposable Can or M ulti-C an M e th o d ..................................................................................................................................1B -26
R efrige ran t Drum M e th o d ...................................................................................................................................................... 1 B -26
C harging th e S y s te m ................................................................................................................................................................1 B -26
A c c u m u la to r A s s e m b ly ........................................................................................................................................................... 1 B -27
S p e cific C om ponent D ia g n o s is ........................................................................................................................................... : .1 B -2 7
C o m p re s s o r............................................................................................................................................................................... 1 B -27
C o n d e n s e r ..................................................................................................................................................................................1B -27
E xpansion V a lv e ........................................................................................................................................................................ 1 B -27
E v a p o r a to r ..................................................................................................................................................................................1 B -27
R efrige ran t Line R e s tric tio n s ............................................................................................................................................... 1 B -28
R efrigerant-11 Flushing P r o c e d u r e .................................................................................................................................... 1 B -28
O n-V ehicle S e r v ic e ...................................................................................................................................................................... 1 B -29
C om pre ssor R eplacem ent (R /V )...........................................................................................................................................1 B -29
C o m pre ssor R eplacem ent (G )................................................................................................................................................1 B -30
1B-2 AIR CONDITIONING

CONTENTS (CONTINUED)
SUBJECT
PAGE
A/C SystemR/V Series.............................................................................................................................................. 1B-34

Condenser Replacement.......................................................................................................................................... 1B-34
Accumulator Replacem ent...................................................................................................................................... 1B-35
Blower Assembly Replacem ent..............................................................................................................................1B-35
Evaporator Core Replacem ent................................................................................................................................1B-36
Orifice (Expansion Tube) Replacement................................................................................................................. 1B-36
Selector Duct and Heater Core Replacement....................................................................................................... 1B-36
Actuator-Plenum Side Vent Replacement............................................................................................................. 1B-37
Plenum Valve R eplacem ent....................................................................................................................................1B-37
Control Assembly Replacement..............................................................................................................................1B-39
Temperature Door Cable A d ju s tm e n t................................................................................................................... 1B-40
Blower Switch Replacement....................................................................................................................................1B-40
Vacuum Tank R eplacem ent....................................................................................................................................1B-41
Blower Motor Resistor Replacement......................................................................................................................1B-41
Blower Motor Relay R eplacem ent..........................................................................................................................1B-41
Fuse Replacement......................................... ....................................................................................................... 1B-43
Vacuum Line Replacement Engine Com partm ent...........................................................................................1B-43
Vacuum Line Replacement Dash........................................................................................................................1B-43
Refrigerant-12 Hose R o u tin g ..................................................................................................................................1B-43
Rear Interior Roof Mounted SystemS u b u rb a n ..................................................................................................... 1B-46
Rear Duct Replacement............................................................................................................................................ 1B-46
Blower Motor Resistor Replacement......................................................................................................................1B-46
Blower Motor Assembly Replacement....................................................................................................................1B-49
Expansion Valve Replacement................................................................................................................................1B-49
Evaporator Core Replacement................................................................................................................................1B-49
Blower Motor Switch Replacem ent........................................................................................................................1B-50
Fuse Replacement.................................................................................................................................................... 1B-50
A/C SystemG S e rie s ................................................................................................................................................ 1B-50
Condenser Replacement.......................................................................................................................................... 1B-50
Accumulator Replacem ent...................................................................................................................................... 1B-50
Heater Core Replacement........................................................................................................................................ 1B-51
Orifice (Expansion Tube) Replacement................................................................................................................. 1B-53
Blower Motor Insulation (w/Diesel) Replacement................................................................................................. 1B-53
Evaporator Core (w/Diesel) Replacem ent............................................................................................................. 1B-53
Evaporator Core Replacem ent................................................................................................................................ 1B-53
Blower Motor Replacement...................................................................................................................................... 1B-54
Control Assembly Replacement.............................................................................................................................. 1B-55
Temperature Door Cable A d ju s tm e n t....................................................................................................................1B-55
Blower Switch Replacement.................................................................................................................................... 1B-57
Resistor Replacement.............................................................................................................................................. 1B-57
Blower Motor Relay R eplacem ent..........................................................................................................................1B-57
A/C Ductwork Replacem ent.................................................................................................................................... 1B-57
Defroster Duct Replacement.................................................................................................................................... 1B-57
Temperature Door Cable Replacem ent..................................................................................................................1B-57
Vacuum Tank Replacem ent.................................................................................................................................... 1B-57
Vacuum Lines-Engine Com partm ent......................................................................................................................1B-57
Refrigerant-12 Hose Routing .................................................................................................................................. 1B-58
Rear Interior Roof Mounted SystemsG S e rie s ..................................................................................................... 1B-63
A/C SystemP Series...................................................................................................................................................1B-65
S pe cifica tio n s............................................................................................................................................................... 1B-66
Special T o o ls ................................................................................................................................................................. 1B-68
AIR CONDITIONING 1B-3
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
P ow er E le m e n t T h e rm o b u lb
C ove r
D ia p h ra g m B ack-up P late
Body
S creen
O rific e
C a rria g e S p rin g
8.
9.
10.
11.
12.
A.
B.
S p rin g S eat
C a rria ge Seat
Seat
A c tu a tin g Pin
D iap hrag m
In le t
O u tle t
F-00190
A.
B.
C.
15.
16.
17.
18.
19.
In le t
O u tle t
R e frig e ra n t V a po r O u tle t
B a ffle
In te rn a l Tube
D e s ic c a n t Bag A s s e m b ly
F ilte r A s s e m b ly
O il B leed H ole
F-00191
Figure 1Thermostatic Expansion Valve
Figure 2Accumulator R/V & G Series
CCOT A/C SYSTEM
During cooling, the air is cooled by the evaporator to

below comfort level then warmed by the heater to the
d e s ire d te m p e ra tu re . D u rin g h e a tin g o n ly th e
evaporator does not operate, and ambient air is warmed
to the desired level in the same manner.
The CCOT (Cycling Clutch Orifice Tube) A/C system

perform s heating and cooling. Air enters the vehicle and
passes through the cooling unit (evaporator) and through
(or around) the heating unit. The system is called a
reheat system. The evaporator cools the air passing
through the core when the air conditioning system is in
the cooling mode.
On R/V and G series, a pressure sensing switch,
lo ca te d n ear the top of the a ccu m u la to r, c o n tro ls
compressor operation. The switch responds to pressure
changes to turn the compressor ON or OFF.
REAR INTERIOR ROOF

MOUNTED SYSTEMS
(SUBURBAN & G SERIES)
These systems operate with the front system - they do
not operate independently. However, control of the rear
System operation:
Outside air or recirculated air enters the system and is
forced through the system by the blower. As the air
passes throught he evaporator core, it receives maximum
cooling if the air conditioning controls are positioned for
cooling.
From the evaporator, the air enters the heater and air
conditioner selector duct assembly where, by means of
diverter doors, it passes through or bypasses the heater
core in proportions necessary to provide the desired
outlet temperature. The air enters the vehicle through
either the floor distributor duct or the dash outlets.
F. In le t
G. O u tle t (To Evaporator)
H. D ent On Tube (R e ta in s th e E x p a n s io n Tube)
20. O u tle t S creen
22. In le t S creen
21. E x p a n s io n Tube
23. Seal
B-07208
Figure 3Orifice (Expansion Tube)

blower motor speed is possible when the front system is
OFF. Rear air circulation w ithout the refrigerant function is
possible by operating the rear blower control switch.
T h e s e s e lf-c o n ta in e d u n its o p e ra te on in s id e
(recirculated) air. Air enters the unit and passes through
the evaporator core into the passenger compartm ent
through the air distributor duct. The front system controls
the rear system. A three-speed blower switch controls the
rear interior roof mounted system.
SYSTEM COMPONENTS
THERMOSTATIC EXPANSION VALVE
Suburban and G rear interior roof mounted and motor
home chassis systems use a therm ostatic expansion
valve (figure 1).
The valve co n sists of the pow er e lem ent, body,
actuating pins, seat and orifice. At the high pressure
liquid inlet, a fine mesh screen prevents dirt, filings or
other foreign matter from entering the valve orifice.
When the valve is connected in the system, high
pressure liquid refrigerant enters the valve through the
screen from the receiver-dehydrator or condenser and
passes on to the seat and orifice where it changes into a
low pressure liquid.
The low pressure liquid leaves the valve and flows into
the evaporator core where it absorbs heat from the
evaporator core and changes to a low pressure vapor and
leaves the evaporator core. The power element bulb is
clamped to the low pressure vapor line just beyond the
outlet of the evaporator.
ACCUMULATOR R/V & G SERIES

The accum ulator is located at the evaporator outlet. It
separates liquid retained from vapor, retains the liquid and
releases the vapor to the compressor (figure 2).
Flow from the accum ulator to the compressor consists
of vapor, entrained liquid and liquid flow through the oil
bleed hole.
A bag of desiccant (dehydrating agent), located in the
accumulator, collects moisture.
There is no sight glass in the accum ulator with the
CCOT system.
ORIFICE (EXPANSION TUBE) R/V & G SERIES

P ressure d iffe re n c e s and su b -co o lin g d ete rm ine s
expansion tube flow. The o rifice is located in the
evaporator inlet line (figure 3).
CYCLING PRESSURE SWITCH

This switch controls evaporator temperature. It cycles
th e c o m p re s s o r c lu tc h o ff w h e n th e e v a p o ra to r
temperature gets too low. It cycles the compressor back
on after evaporator tem perature has increased (figure 4).
Figure 4Pressure Cycling Switch

T he c y c lin g p re s s u re s w itc h p ro v id e s in h e re n t
compressor protection so a separate low pressure switch
is not necessary. The switch also acts as an ambient
switch since at ambient freezing temperatures it will not
allow the compressor to engage. Adjusting the set screw
one-half turn left or right will rise or lower the settings 20.7
kPa (3 psi).
C ycling Pressure S w itch S e ttin g (A ccu m u la to r

Readings)
Commpressor Cut Out Pressure
R a n g e .................................................71-81 kPa (21-24 psi)
Compressor Cut In Pressure
R a n g e ......................................145.2-165.4 kPa (43-49 psi)
PERIODIC MAINTENANCE
AND SERVICING
Inspect the system once a year, preferably in the spring
before warm weather.
Check refrigerant lines for leaks.
Check refrigerant charge; evaluate and recharge as
necessary.
SYSTEM OPERATION RV & G

For information on selector switch, select valve and fan
switch operating characteristic, refer to figures 5 and 6.
FUNCTIONAL TESTRV & G

To check the operation of the control assembly, perform
these tests as one complete operation, refer to figures 7
and 8.
SELECTOR SWITCH OPERATING CHART
CONNECTION
TERMINAL
NUMBER
OFF
MAX A/C
NORM A/C
BI-LEV A/C
VENT
HEATER
DEFROST
FAN SWITCH
NONE
3, 5
3, 5
3, 5
3, 5
COMPRESSOR
NONE
2, 5
2, 5
2, 5
NONE
NONE
2, 5
NOT USED
BATTERY +
2, 3
NOT USED
NONE
2, 3
2, 3
2, 3
SELECT VALUE OPERATING CHART

PORT
OFF
MAX A/C
NORM A/C
BI-LEV A/C
VENT
HEATER
DEFROST
INPUT
2, 4
NONE
3, 5
A/C MODE
VENT
1, 4
VENT
VENT
VENT
HTR MODE
VENT
VENT
VENT
VENT
1, 5
OUTSIDE AIR/
RECIRCULATION
VENT
1, 2
VENT
VENT
VENT
VENT
VENT
DEFROST
VENT
VENT
VENT
VENT
VENT
VENT
VENT
NOT USED
CONNECTION
SEALED IN THE CONNECTOR

BLOWER SWITCH
POSITIONS
LO
MEDIUM 1
MEDIUM 2
HI
BATTERY +
NONE
MEDIUM 1
MEDIUM 2
HI
HI
NONE
NONE
NONE
BATTERY +
MEDIUM 1
NONE
BATTERY +
NONE
NONE
NONE
NONE
BATTERY +
NONE
TERMINAL
MEDIUM 2
B-08404
Figure 5System Operation R/V
HI
j----------AIRCOND.--------- 1 j-E C O N O M Y -|
OFF
MAX
NORM
BI-LEV
VENT
HEAT
DEFM W
__ a____! ____ a___ ____
COLD r "
1 HOT
LO
SELECTOR SWITCH OPERATING CHART
CONNECTION
TERMINAL
NUMBER
OFF
MAX A/C
NORM A/C
BI-LEV A/C
VENT
HEATER
DEFROST
FAN SWITCH
NONE
3, 5
3, 5
3, 5
3, 5
COMPRESSOR
NONE
2, 5
2, 5
2, 5
NONE
NONE
2, 5
NOT USED
BATTERY +
NONE
2, 3
2, 3
2, 3
VENT
HEATER
DEFROST
VENT
VENT
VENT
NOT USED
2, 3
SELECT VALUE OPERATING CHART

CONNECTION
PORT
OFF
MAX A/C
1
OUTSIDE AIR/
RECIRCULATION
NORM A/C
BI-LEV A/C
NOT USED - SEALED IN THE CONNECTOR

VENT
VACUUM
VENT
VENT
HEAT - DEF
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
VENT
INPUT
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
A/C MODE
VENT
VACUUM
VACUUM
VENT
VACUUM
VENT
VENT
VENT
VENT
BI-LEVEL
VENT
VACUUM
VACUUM
VACUUM
VACUUM
BLOWER SWITCH
POSITIONS
TERMINAL
LO
MEDIUM 1
MEDIUM 2
BATTERY +
NONE
MEDIUM 1
MEDIUM 2
HI
HI
NONE
NONE
NONE
BATTERY +
MEDIUM 1
NONE
BATTERY +
OPTIONAL
NONE
MEDIUM 2
NONE
NONE
BATTERY +
OPTIONAL
HI
B-08715
Figure 6System Operation G

R/V Functional Test Air Conditioning
P erform th is te s t as o ne o p e ra tio n by o n e in s p e c to r in o n e s ta tio n o ff roll te s t.
SYSTEM RESPONSE
CONTROL SETTINGS
STEP
MODE
CONTROL
TEMPERATURE
CONTROL
FAN
SWITCH
BLOWER
SPEED
HEATER
OUTLETS
A/C
OUTLETS
DEFROSTER
OUTLETS
OFF
COLD
OFF
OFF
NO AIR FLOW
NO AIR FLOW
NO AIR FLOW
MAX
COLD
LO
LOW
NO AIR FCOW
AIR FLOW
NO AIR FLOW
MAX
COLD
LO TO HI
LOW TO HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
NORM
COLD
LO TO HI
LO TO HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
BI-LEV
COLD
HI
HI
AIR FLOW
AIR FLOW
MIN AIR FLOW
VENT
COLD
HI
HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
HTR
HOT
HI
HI
AIR FLOW'
NO AIR FLOW
MIN AIR FLOW
A, D
HOT
HI
HI
MIN AIR FLOW
NO AIR FLOW
AIR FLOW
SEE
REMARKS
REM ARKS
A. D e te n t e n g a g e m e n t m u s t be fe lt in each m ode.
B. B lo w e r speed in cre a se m u s t o c c u r fro m low, m e d iu m 1, m e d iu m 2, and h ig h.
C. L is te n fo r th e re d u c tio n o f a ir n o ise d ue to re c irc u la tio n d o o r c lo s in g .
D. ^C heck te m p e ra tu re lever fo r e ffo rt.
N O T E ' C h e ck o u tle ts for:
1. Barrel ro ta tio n .
2. Vane o p e ra tio n .
3. Barrel and vanes m u s t h o ld p o s itio n in h ig h blow er.
^ ^ o ld /H o T A i^
1. W ith th e m od e lever in m a x im u m , th e te m p e ra tu re lever in c o ld , th e -blow e r s w itc h in h ig h , th e
te m p e ra tu re fro m th e c e n te r o u tle t s h o u ld d ro p 2 0 fro m th e te m p e ra tu re o u ts id e th e v e h ic le (in room
te m p e ra tu re o r w a rm e r c o n d itio n s ).
2. W ith th e m od e lever in
(d e fro st), th e te m p e ra tu re lever in h o t, th e b lo w e r s w itc h in h ig h , th e
te m p e ra tu re fro m th e d e fro s t o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e ve h ic le .
B-08705
F ig u re 7 F u n c tio n a l T e s t R /V

G Functional Test Air Conditioning
P erform th is te s t as o ne o p e ra tio n by o n e in s p e c to r in o n e s ta tio n o ff roll te s t.
CONTROL SETTINGS
SYSTEM RESPONSE
STEP
MODE
CONTROL
TEMPERATURE
CONTROL
FAN
SWITCH
BLOWER
SPEED
HEATER
OUTLETS
A/C
OUTLETS
DEFROSTER
OUTLETS
OFF
COLD
OFF
OFF
NO AIR FLOW
NO AIR FLOW
NO AIR FLOW
MAX
COLD
LO
LOW
NO AIR FLOW
AIR FLOW
NO AIR FLOW
MAX
COLD
LO TO HI
LOW TO HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
NORM
COLD
HI
HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
A, C
BI-LEV
COLD
HI
HI
AIR FLOW
AIR FLOW
NO AIR FLOW
VENT
COLD
HI
HI
NO AIR FLOW
AIR FLOW
NO AIR FLOW
HTR
HOT
HI
HI
AIR FLOW
NO AIR FLOW
MIN AIR FLOW
A, D
HOT
HI
HI
MIN AIR FLOW
NO AIR FLOW
AIR FLOW
SEE
REMARKS
REMARKS
A. D eten t e n g a g e m e n t m u s t be fe lt in each m ode.
B. B lo w e r sp ee d in cre a se m u s t o c c u r fro m low, m e d iu m 1, m e d iu m 2, and h ig h .
C. L iste n fo r th e re d u c tio n o f a ir n o is e d u e to re c irc u la tio n d o o r c lo s in g .
D. C h e ck te m p e ra tu re lever fo r e ffo rt.
N O TE C h e ck o u tle ts for:
1. Barrel ro ta tio n .
2. Vane o p e ra tio n .
3. Barrel and vanes m u s t h o ld p o s itio n in h ig h blow er.
Cold/Hot Air Check

1. W ith th e m o d e lever in m a x im u m , th e te m p e ra tu re lever in c o ld , th e b lo w e r s w itc h in h ig h , th e
te m p e ra tu re fro m th e c e n te r o u tle t s h o u ld d ro p 2 0 fro m th e te m p e ra tu re o u ts id e th e v e h ic le (in room
te m p e ra tu re o r w a rm e r c o n d itio n s ).
2. W ith th e m o d e lever in
(d e fro st), th e te m p e ra tu re lever in h o t, th e fan s w itc h in h ig h , th e te m p e ra
tu re fro m th e d e fro s t o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e v e h ic le .
F igure 8-F u n ctio n a l T est G
REFRIGERANT-12 OPERATING CHARACTERISTICS

SYSTEM COMPONENTS,
TEMPERATURE AND
PRESSURE RELATIONSHIPS
To review system components and Refrigerant-12 flow,
refer to figure 9.
To find the pressure and tem perature relationship
between Refrigerant-12 and atmospheric pressure, refer
to figure 10.
REFRIGERANT AND OIL CAPACITY

The refrigerant system requires refrigerant and oil in
quantities listed:
1. Refrigerant-12
C60 System
R/V M o d e ls ............................ 1.588 Kg (3 lbs. 8 ozs.)
G M odels.................................1.588 Kg (3 lbs. 8 ozs.)
Rear In te rio r S ystem
RA?- M o d e ls ............................ 2.381 Kg (5 lbs. 4 ozs.)
G M od els.................................2.041 Kg (4 lbs. 8 ozs.)
2. 525 Viscosity Oil 0.284 Kg (10 oz.).
HANDLING REFRIGERANT-12
A ir co nditioning system s contain Refrigerant-12, a
c h e m ica l w hich requires sp ecial h an dling to avoid
personal injury.
Always wear goggles and wrap a clean cloth around
fittin g s , valves and co n n e ctio n s when o pening the
system. Work in a ventilated area and do not weld or
steam clean near air conditioning lines or components.
Refrigerant-12 drums are shipped with a metal screw
cap that protects the valve and safety plug from damage.
Replace the cap after each use.
Do not carry a co nta ine r of Refrigerant-12 in the
passenger compartment of a vehicle. Never subject any
container to high temperatures. Do not breathe the smoke
or fumes produced by burning Refrigerant-12.
If R e frig e ra n t-1 2 to u c h e s e xp o se d fle sh do th e
following:
Treat the area as if it were frost bitten or frozen.
Call a doctor or eye specialist and obtain treatment.
DO NOT RUB THE EYE. Splash the area with cold
water to raise temperature above the freezing point.
Use an antiseptic oil to provide a protective film over
the eyeball to reduce the possibility of infection.
HANDLING OF REFRIGERANT
LINES AND FITTINGS
Tighten tubing connections to the specified torque
(figure 11). Insufficient or excessive torque causes loose
joints or deformed joint parts. Either condition can cause
refrigerant leakage.
All metal tubing lines should be free of dents or
kinks to prevent loss of system capacity due to a line
restriction.
Never bend a flexible hose line to a radius of less

than 4 times the diameter of the hose.
Never place a flexible hose line closer than 65 mm
(2 1/2-inch) to the exhaust manifold.
Inspect flexible hose lines regularly for leaks or
brittleness and replace if necessary.
When disconnecting any fitting in the refrigeration
system discharge the system. However proceed with
caution. Open slowly. Keep face and hands away to
prevent injury if there is liquid Refrigerant-12 in the
line. Allow any pressure to bleed off as described
under Discharging, Evacuating, Adding Oil And
Charging And Discharging The System .
Cap or tape any line open to atmosphere to prevent
dirt and moisture from entering the system.
Use proper wrenches when making connections on
seal (o-ring) fittings. Use two wrenches to prevent
distorting the lines or components.
When connecting the flexible hose connections,
hold the swaged fittin g , the flare nut and the
coupling at the same time using three different
w re n c h e s to p re v e n t tu rn in g th e fittin g and
damaging the ground seat.
Use seals (o-rings) in good condition. A burr or
piece of dirt may cause a leak.
Replace the seal when a connection has been
broken. When replacing the seal first dip it in clean
525 viscosity refrigeration oil.
When making steel to aluminum connections, use
the torque for aluminum tubing. (Refer to figure 11).
MAINTAINING CHEMICAL
STABILITY
T he e ffic ie n t o p e ra tio n of th e a ir c o n d itio n in g
refrigeration system is dependent upon the chemical
stability of Refrigerant-12.
F o re ig n m a tte r ca n c h a n g e th e s ta b ility of
R efrige ran t-12 , ca use c o rro s io n and wear. Do the
following:
1. Before disco nn ectin g a refrigerant connection,
remove dirt or oil at and near the connection. Cap or
plug both sides of the connection.
2. Keep tools clean and dry.
3. When adding 525 viscosity refrigerant oil (refer to
ADDING O IL in the D ischa rg ing , E vacuating,
Adding Oil and Charging Procedures for CCOT A/C
systems), the transfer device and container should
be clean and dry.
4. Have everything ready before opening a line. Do not
leave the A/C system open longer than necessary.
5. After opening, evacuate before recharging with
R efrigerant-12 a ccordin g to the D ischarging,
Evacuating, Adding Oil, Charging And Discharging
The System .
6. Service parts are dehydrated and seated before
shipping. Open just before making connections.
Keep at room temperature before uncapping (this
prevents moisture from entering the system). If the
connections are not made, reseal the parts.
33.
130.
124.
600.
601.
604.
605.
606.
606
L. H P V - H ig h p re s s u re v a p o r lea ving c o m p re s s o r.
M. HPL - V a po r is c o o le d d o w n by c o n d e n s e r a ir flo w
and leaves as h ig h p re s s u re liq u id .
N. LPL - O rific e m e te rs th e liq u id R-12 in to e v a p o ra -.
tor, re d u c in g its p re s s u re and w arm b lo w e r a ir
a c ro s s e v a p o ra to r co re c a u s e s b o ilin g o ff o f liq u id
in to vapor.
A c c u m u la to r
E xa p a n sio n Tube (O rifice )
E va po rato r
C o m p re s s o r
C ondenser
P ressure C y c lin g S w itc h
O il B leed H o le
D e s s ic a n t Bag
O. L P V - Leaves e v a p o ra to r as lo w p re s s u re v a p o r
and re tu rn s w ith th e s m a ll a m o u n t o f . . .
P. L P V /lp i - Low p re s s u re liq u id th a t d id n t b o il o ff
c o m p le te ly b a ck to th e c o m p re s s o r to be c o m
p re ssed a ga in .
F-00075
Figure 9 S ystem C om po n en ts
REFRiGERANT - 12
PRESSURE - TEMPERATURE
RELATIONSHIP
The table below indicates the pressure of Refriger
ant - 12 at various temperatures. For instance, a
drum of Refrigerant at a temperature of 26.6C
(80F) will have a pressure of 579.9 kPa (84.1 psi).
If it is heated to 51.6C (125F), the pressure will
increase to 1 154.9 kPa (167.5 psi). It also can be
used conversely to determine the temperature at
which Refrigerant - 12 boils under various pres
sures. For example, at a pressure of 207.5 kPa
(30.1 psi), Refrigerant - 12 boils at 0C (32F).
kPa
PSIG
kPa
PSIG
-29.8
21.7
-28.8
-23.3
-20.5
-17.7
-15.0
-12.2
- 9.4
- 6.6
- 3.8
- 1.1
0
1.6
4.4
7.2
10.0
-2 0
-1 0
-5
0
5
10
15
20
25
30
32
35
40
45
50
16.5
31.0
46.9
63.4
81.4
101 4
17.7
145.5
169.6
196.5
207.5
224.8
255.1
287.5
322.0
Atmos
pheric
Pressure
2.4
4.5
6.8
9.2
11.8
14.7
122.0
21.1
24.6
28.5
30.1
32.6
37.0
41.7
46.7
12.7
15.5
18.3
21.1
23.8
26.6
29.4
32.2
35.0
37.7
40.5
43.3
46.1
48.8
51.6
54.4
60.0
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
140
358.5
397.8
439.2
482.7
530.2
579.9
632.3
686.7
745.3
806.0
870.2
937.7
1010.1
1083.2
1154.9
1234.2
1410.0
52.0
57.7
63.7
70.1
76.9
84 1
91.7
99.6
108.1
116.9
126.2
136.0
146.5
157.1
167.5
179.0
204.5
F igure 10 P ressure T em p eratu re R ela tion ship o f R efrigerant-12
F -00 17 7
M e ta l T ube
O u ts id e
D ia m e te r
S tee l
T u b in g
T o rq u e
T h re a d and
F ittin g Size
7/l6
5/s
3/4
7I&
11/l6
1/4
3/8
1/2
5ls
3/4
A lu m in u m o r
C opper
T u b in g
T o rq u e
N-m
14-20
41-48
41-48
41-48
41-48
LB. FT.
10-15
30-36
30-36
30-36
30-36
N-m
7-8
15-18
20-27
28-37
36-45
N o m in a l
T o rq u e
W re n c h S pan
LB. FT.
5-7
11-13
15-20
21-22
28-33
5/s
3/4
7/8
11/l6
1V4
F-00161
Figure 11Pipe and Hose Connections Torque
REFRIGERANT SYSTEM DIAGNOSIS

NOTICE: When performing air conditioning di
agnosis on vehicles equipped with a catalytic
converter, warm the engine to a normal operat
ing temperature before attem pting to idle the
engine for periods greater than five minutes.
INSUFFICIENT COOLING
QUICK-CHECK PROCEDURE
Use the following Hand-Feel procedure if the system
has the pro pe r charge of R efrigerant-12 (provid in g
ambient temperature is above 21 C (70F).
1. Engine must be warm and at normal idle speed.
2. Hood and body doors open.
3. Selector (mode) lever set at NORM.
4. Temperature lever at COLD.
5. Blower on HI.
6. Hand-Feel the temperature of the evaporator inlet
pipe after the orifice and accum ulator with the
compressor engaged.
BOTH THE SAME TEMPERATURE AND SOME
DEGREE COOLER THAN AM BIEN T Proper
condition: check for other problems (refer to A/C
System Diagnostic Procedure).
IN LE T PIPE C O O LER TH AN ACCUM ULATOR
SURFACE indicates a low refrigerant charge.
Add amounts 0.113 kg (4 oz.) of refrigerant
UNTIL BOTH feel the same temperature. Allow
stabilization time between additions.
Then add 0.397 kg (.88 lbs.) one can additional
refrigerant. The 0.397 kg/14 oz. disposable can
of Refrigerant-12 is the equivalent to .88 lbs.).
SYSTEM PERFORMANCE TEST
1.
2.
3.
4.
5.
6.
7.
Tool Required:
J-21213-A Four Jack-Dual Range Temperature
Tester
Open doors or windows.
Position the right lever in the NORM mode.
Place the left lever in the cold (blue) position.
Place the blower switch at H I.
Install J-21213-A at the instrum ent panel right outlet.
Start the engine and run at 2000 rpm.
After one minute, the minimum drop in temperature
from the center outlet should be:
Condenser Inlet
Temperature
Instrument Panel
Right Outlet
Temperature
(Minimum Drop)
21 C
(70 F)
26C
(80F)
32-43C
[90-110F)
-7C
-4C
-1 C
(20 F)
(25 F)
(30F )
TESTING THE
REFRIGERANT SYSTEM
If a malfunction is suspected due to abnormal system
pressures, check the following:
1. Outer radiator and condensor cores for plugging.
Check between the condenser and radiator.
2. R e s tric tio n s o r k in k s in e v a p o ra to r c o re or
condensor core, hoses, tubes, etc.
3. Refrigerant leaks.
4. Air ducts for leaks or restrictions. Air restriction may
indicate a plugged (or partially plugged) evaporator
core.
5. Compressor clutch slippage.
6. Improper drive belt tension.

INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH-EXPANSION TUBE (PRESSURE SENSING)
C O N TIN U ED ON FO LLO W ING PAGE
F-02215
Figure 12Insufficient Cooling Diagnosis
F-02653
F igu re 12 In s u ffic ie n t C oo lin g D iagnosis (C ont.)
7. Plugged accumulator, orifice (expansion tube) or
plugged suction inlet screen (A6 compressor).
8. Moisture in the refrigerant system.
LEAK TESTING THE

REFRIGERANT SYSTEM
J-29547AUTO BALANCE REFRIGERANT
LEAK DETECTOR
Electronic circuitry detects refrigerant or halogen gas
leaks as small as 1/2 oz. per year. J-29547 features a
slide-type on-off sw itch that also resets the unit in
contaminated areas.
Audible and visual leak detection is provided by a
change in signal tone and flashing LED built into the 45.7
cm (18-inch) flexible probe. A 102 cm (40-inch) coiled
extension permits detection in hard to reach places.
A green LED battery life monitor glows to indicate

sufficient operating voltage when the unit is on. Field
service is possible with replacement tips, filters and a
sensing element which can be cleaned with common
solvent.
PRESSURE SENSING SWITCH

A pressure sensing switch located near the top of the
accumulator, cycles the compressor clutch on R/V and G
series systems. The switch also shuts off the compressor
clutch when there is a low refrigerant charge.
The A/C system does not have to be discharged to
replace the switch. The pressure switch fitting is equipped
with a schrader-type valve.
W hen replacing the switch, use a new oiled seal
(o-ring), and torque to 10 N-m (90 in. lbs.).
Refer to the following trouble shooting charts:
1. Insufficient Cooling Diagnosis (figures 12, 13, 14,
and 15).
2. Compressor Diagnosis (figure 16).

OFF ALL THE TIME
CHART A
F igure 13 In s u ffic ie n t C oo lin g D iagnosis C hart A

INLET PIPE COLDER THAN OUTLET PIPE
CHART B
Figure 14 In s u ffic ie n t C oo lin g D iagnosis C hart B
CHECK COMPRESSOR CYCLING

CHART C
B -08574
F ig u re 1 5 In s u ffic ie n t C o o lin g D ia g n o s is C h a rt C
COMPRESSOR DIAGNOSIS
F -0 2 3 3 3
Figure 16Compressor Diagnosis
ELECTRICAL/VACUUM TROUBLE DIAGNOSIS

When diagnosing problems in the electrical and vac
uum systems, refer to System Operation and Func
tional Test. For electrical wiring and vacuum diagrams,
refer to figures 17, 18, 19, and 20.
Ports on rotary vacuum valves are illustrated to provide
simplicity in following vacuum schematic lines but are
numbered in consecutive order on the actual valve.
OPERATIONAL TEST
To determine if the electrical, vacuum and refrigeration
systems are operating efficiently, do the following:
1. Operate the blower at four speeds and check the

compressor clutch engagem ent. This indicates that
the electrical circuits are working.
2. Check the hand felt temperature of the evaporator
inlet pipe and accum ula tor surface. The same
temperature indicates a properly charged system.
3. Operate the A/C control selector (mode) lever to
distribute air from the outlets. This will check the
vacuum and diaphragm function.
45
46
47
53
53
A
K
/
Select Lever Valve Operation Chart
Port
Max A/C Norm A/C Bi-Level
Vent
Heat
Defrost
V a cuu m
V a cuu m
V a cu u m
V a cu u m
V a cu u m
V a cu u m
Vent
V a cuu m
V a cuu m
V a cu u m
V a cuu m
V a cu u m
Vent
V a cuu m
V a cuu m
V a cuu m
Vacuum
V a cuu m
V a cu u m
Vent
Vent
Vent
Connection
No.
Off
S o u rce
V a cuu m
Bi Level
H e a t/D e fro s t
O S A /R E C
Vent
V a cuu m
Vent
Vent
Vent
Vent
AC M od e
Vent
V a cuu m
V a cuu m
Vent
Vent
Vent
P o rts 1,6,7 & 8 N o t U sed (Sealed On V a cu u m H o s e A s s e m b ly )
45.
46.
47.
52.
53.
V a cu u m S o u rce - E n g in e
V a cu u m Tank - G as
C ow l
C o n tro l
A c tu a to r
I.
E.
H.
K.
F.
V a cuu m
V a cuu m
V a cu u m
V a cu u m
V a cuu m
L in e
Lin e
Lin e
L in e
L in e
Tan (S ource)
G ray (Bi Level)
D ark B lu e (A/C)
Red (H e a t/D e fro s t)
O ran ge (R e c irc u la te )
Figure 17G Vacuum Schematic
B-06944
ELECTRICAL SYSTEM DIAGNOSTIC CHART

BLOW MOTOR INOPERATIVE
(ANY SPEED)
CHECK FOR PROPER
FUSE.
JL
r
FUSE BLOWN
FUSE OK |
WITH IGNITION SWITCH IN "R U N POSITION AND

HEATER OR A/C ON, LOCATE SHORT IN ONE OF THE
FOLLOWING WIRES: (SEE NOTE)
1. FROM FUSE PANEL TO MASTER SWITCH ON
CONTROL.
2. FROM MASTER SWITCH TO COMPRESSOR
CLUTCH.
3. MASTER SWITCH TO BLOWER SWITCH.
4. FROM BLOWER SPEED SWITCH TO RESISTOR.
5. FROM RESISTOR TO BLOWER MOTOR.
NOTE: SHORT CIRCUIT MAY BE INTERMITTENT. IF
TESTER DOES NOT INDICATE A SHORT CIRCUIT,
MOVE HEATER HARNESS AROUND AS MUCH AS
POSSIBLE TO RECREATE SHORT CIRCUIT. WATCH
AND LISTEN FOR ARCING.
THE FOLLOWING TESTS SHOULD BE MADE WITH

THE IGNITION SWITCH IN RUN" POSITION,
HEATER OR A/C ON AND BLOW SWITCH ON
HIGH.
CHECK BLOWER MOTOR GROUND.
| POOR OR NO GROUND |
| GROUND O K ]
CHECK MOTOR CONNECTOR
WITH 12 VOLT TEST LIGHT
j REPAIR GROUND j
LAMP ON
LAMP DOES NOT LIGHT
REPLACE MOTOR
CHECK WIRE CONNECTOR ON BLOWER

RELAY WITH 12 VOLT TEST LIGHT.
LAMP ON
X
REPAIR OPEN IN WIRE
FROM BLOWER MOTOR
TO BLOWER RELAY.
LAMP DOES NOT LIGHT

C
CHECK WIRE CONNECTOR ON
BLOWER RELAY WITH 12 VOLT
TEST LIGHT.
_r
LAMP DOES NOT LIGHT
USE 12 VOLT TEST LIGHT AND

CHECK WIRE TERMINALS AT
RESISTOR.
1
LAMP ON
T
| REPLACE RELAY |
LAMP OFF
LAMP ON
CHECK FEED WIRE FROM

RESISTOR TO BLOWER
SPEED SWITCH.
r
LAMP ON
---------------1
REPLACE RESISTOR.
LAMP OFF
REPLACE BLOWER
SPEED SWITCH.
REPLACE OPEN IN WIRE

FROM BLOWER SPEED
SWITCH.
F -0 0 1 6 7
Figure 18Electrical System Diagnostic Chart
ELECTRICAL SYSTEM DIAGNOSTIC CHART (CONTINUED)
F-00669
Figure 19Electrical System Diagnostic Chart
Port
Connection
No.
S o u rce
A/C M od e
Select Lever Valve Operation Chart

Off
Max A/C
V ent
V acuum
H e a te r/M o d e
Vent
O p tio n a l
O p tio n a l
Vent
O p tio n a l
Vent
V a cuu m
O S A/R EC
V acuum
Vent
Vent
Vent
Vent
V a cuu m
V acuum
D e fro s te r
V e nt
V acuum
V acuum
Vent
V acuum
V ent
Vent
Norm A/C
Bi-Level
Vent
Heat
vac
Defrost
P o rts 6,7,8 and 9 n o t used (sealed on v a c u u m h o se a s s e m b ly )
45.
46.
47.
48.
V a cuu m S o u rce - E n gin e

V a cuu m Tank (Gas)
C ow l
P le nu m Valve
49.
50.
51.
53.
M od e D o o r
D e fro s te r D o o r
R e c irc u la to r D o o r
A c tu a to r
E.
F.
H.
|.
J.
V a cuu m
V a cuu m
V a cuu m
V a cuu m
V a cuu m
L in e
L in e
L in e
L in e
L in e
G a ry (Source)
O ran ge (D e froster)
D ark B lue (Heat)
Tan (A/C)
B la c k (D efroster)
F-00182
Figure 20R/V Vacuum Schematic
VACUUM SYSTEM DIAGNOSIS

R/V AND G SERIES
Start the engine and allow it to idle. Move the selector
lever to each position and refer to the vacuum diagrams
and operational charts for airflow, air door functioning and
vacuum circuits. If air flow is not out of the proper outlet at
each selector lever position do the following:
L*
Inspect
1. The hose connections at the vacuum actuators,

control head valve and vacuum tank.
2. The vacuum source circuit:
Install a vacuum tee and gage (with restrictor) at the
vacuum tank outlet. Idle the engine and read the
vacuum (a normal vacuum is equivalent to manifold
vacuum) at all selector lever positions.
Vacuum less than normal at all positions.
Remove the tee and connect the vacuum gage line
to the tank - read the vacuum. If still low, then the
problem lies in the feed circuit, the feed circuit to the
tank or in the tank itself. If vacuum is now normal,
then the problem lies downstream.
Vacuum less than normal at some positions.
If vacuum was low at one or several of the selector
lever positions, a leak is indicated in these circuits.
Vacuum normal at all positions.

If vacuum was normal and even at all positions, then
the m alfunction may be caused by im p rop erly
connected or plugged lines or a m alfunctioning
vacuum valve or valves.
3. Specific vacuum circuit check:
Place the selector lever in the m alfu nctio nin g
position and check for vacuum at the pertinent
vacuum actuators.
If vacuum exists at the actuator but the door does
not move, then the actuator is defective or the door
is jammed.
If low or no vacuum exits at the actuator determine
whether the cause is the vacuum harness or the
vacuum valve.
Check the vacuum harness first.
4. Vacuum harness circuit check:
Disconnect the vacuum harness at the control head.
The black line should show engine vacuum; if not,
trace back through connector to vacuum tank.
To check any individual circuit, place the selector
lever at the involved circuit position and check for
vacuum presence.
EVACUATING AND CHARGING PROCEDURES

EVACUATION AND
CHARGING PROCEDURES
Before opening any refrigerant hose or component,
read the information furnished in:
Refrigerant-12 Operating Characteristics.
Discharging, Evacuating, Adding Oil and Charging.
Remove sealing caps from subassem blies before
m aking connections for final assembly. Use a small
amount of clean 525 viscosity refrigerant oil on all tube
and hose joints.
Use new seal (o-ring) dipped in the clean 525 viscosity
refrigerant oil when assembling joints. The oil will aid in
assembly and help provide a leak-proof joint.
When tightening joints, use a second wrench to hold
the stationary part of the connection.
Tighten all tubing connections (figure 11). Insufficient or
excessive torque can cause loose joints or deformed joint
parts. Either condition can cause leakage.
DISCHARGING, EVACUATING
ADDING OIL AND
CHARGING PROCEDURES
Discharge, evacuate and charge using J-23500-01 air
conditioning service Charging Station or the J-5725-04
Manifold Gage Set, and 0.397 kg. (14 oz.) disposable
cans of Refrigerant-12 (figures 21 and 22).
Use gage adapters to connect the charging lines from

the charging station or manifold and gage set to system
service fittings. A straight gage Adapter J-5420 and a 90
angle gage Adapter J-9459 is available.
Wear goggles and wrap a clean cloth around fittings
and connections.
D is c h a rg e th e sys te m b e fo re re m o v in g
replacing refrigeration lines or components.
and
Use the service valve and pressure gage sets during

evacuation and charging procedures.
Do not charge while the compressor system is hot.
Always discharge the system at the low side service
fitting and perform the evacuation and charging
procedure through the low side service fitting.
Do not connect the high pressure line or any line to
the high side service fitting during discharging and
charging procedures.
CAUTION: Never remove a gage line from its

adapter when the line is connected to the A/C
system. Always remove the line adapter from
the service fitting to disconnect a line. Do not
rem ove ch argin g hose at gage set w h ile
attached to service low side fitting. This will
discharge the system due to the depressed
schrader valve in service low side fitting and
may cause personal injury due to escaping
Refrigerant-12.
55. G age Set

56. V a cuu m P um p
57. E m p ty 3 Lb.
C o ffe e Can
58. R efrigerant-12
quantity in removed parts before evacuation and

c h a rg in g w ith R e frig e ra n t-1 2 (re fe r to C C O T
Refrigerant Oil Distribution for the quantity of oil
normally retained in removed parts).
6. If adding oil is necessary, remove the suction hose
at the accum ulator outlet pipe connection and pour
the correct quantity of refrigerant oil into the hose or
pipe and then reconnect the hose or pipe. (Refer to
step number 4 and Refrigerant Oil Distribution for
specific quantity instructions).
REFRIGERANT
OIL DISTRIBUTION
A-6 COMPRESSOR 0.284 kg. (10 ounces) of 525
viscosity refrigerant oil.
R-4 COMPRESSOR 0.170 kg. (6 ounces). Add new
oil during the following com ponent replacement and
conditions:
1. With no excessive oil leakage, add;
C om pressor - Remove, drain oil, measure
replace the same am ount of new oil plus
0.0284 kg. (1 ounce).
Evaporator - Add 0.085 kg. (3 ounces).
Condenser - Add 0.0284 kg. (1 ounce).
F-00169
Figure 21J-23500-01 Charging Station
DISCHARGING THE SYSTEM

B efore re p la cin g any co m p o n e n t, d is c h a rg e the
system.
1. Discharge at the low side service fitting.
2. With the ignition turned OFF, remove the protective
cap from LOW SIDE service fitting and connect
Charging Station J-23500-01 Gage Set. (Refer to
figure 21).
a. If charging station J-23500-01 is not being
u s e d , d is c h a r g e th e sys te m by s lo w ly
connecting a gage hose to the low side service
fitting on the accum ulator and discharge into a
bottle (figure 23).
b. As the hose is SLOWLY tightened down onto
th e s c h ra d e r v a lv e , R e frig e ra n t-1 2 w ill
discharge from the system into the container. If
no discharge occurs, check for missing or
defective schrader depressor in the hose
fitting.
3. With the low side of the system discharged, check
the high side system fitting (on the liquid line or
muffler) for rem aining pressure.
4. If pressure is found, attempt to discharge the high
side using the same procedure as used for the low
side. (This condition indicates a restriction on the
high side. Diagnose and correct before evacuating
and charging).
5. After discharging, (no vapor escaping with the hose
fu lly-tightened down), m easure and record the
amount. If 0.0014 kg. (.05 ounce) or more, add this
amount of new 525 viscosity refrigerant oil plus any
Accum ulator - R-4 Compressor - Remove drain

oil, measure, replace the same amount of new
oil plus 0.057 kg. (2 ounces) to compensate for
th at retained by the o riginal accum ula tor
dessicant.
DA-6 C o m p re s s o r - R em ove, d ra in o il,
measure, replace same amount of new oil plus
0.085 kg. (3 ounces) to compensate for that
re ta in e d by th e o r ig in a l a c c u m u la to r
dessicant. If no oil can be drained from old
accumulator, add 0.057 kg. (2 ounces) new oil
to the new accumulator.
2. With signs of excessive oil leakage;
A-6 COMPRESSOR
Remove Compressor and Accumulator. Drain
m e a su re and re c o rd to ta l o il fro m both
components. Use new oil.
If less than 0.170 kg. (6 ounces), add 180 ml (6
ounces) of new oil to system.
If more than 0.170 kg. (6 ounces), add the
same amount of new oil as drained.
If a new a c c u m u la to r is in s ta lle d to A-6
system, add 0.057 kg. (2 ounces) additional oil
to compensate for that held/absorbed by the
original accum ulator dessicant.
DA-6 COMPRESSOR
Remove the accumulator. Drain, measure
and record quantity of oil in accumulator. It is
not necessary to remove and drain the DA-6
com pressor because the com pressor only
retains a m inimum quantity of oil, it doesnt
have an oil sump area.
If less than 0.085 kg. (3 ounces) add 0.085 kg.
(3 ounces) of new oil to the system.
If more than 0.085 kg. (3 ounces) add the
65. A c c u m u la to r
F-02407
Figure 22Charging the System with a Disposable Can or Drum

If a new accum ulator is installed add 0.085 kg.
(3 ounces) additional oil to compensate for
that absorbed by the original accum ulator
dessicant.
If less than 0.085 kg. (3 ounces), add 0.085 kg.

(3 ounces) of new oil to system.
R-4 COMPRESSOR
If more than 0.085 kg. (3 ounces), add the

Remove the accumulator. Drain, measure

and record quantity of oil in accumulator. It is
not necessary to remove and drain the R-4
com pressor because the com pressor only
retains a minumum quantity of oil.
If a new accum ulator is installed to system,

a dd 0 .0 5 7 (2 o u n c e s ) a d d itio n a l o il to
compensate for that retained by the original
accum ulator dessicant.
EVACUATING AND CHARGING

Before charging, evacuate the system if Refrigerant-12
is lost or if the system has been opened.
Evacuation and charging is a combined procedure.
Purge all gage lines with Refrigerant-12 before charging.
There are three standard Refrigerant-12 evacuate and
charge procedures:
J-23500-01 Charging Station Method
Disposable Can Method
Drum Method
Figure 23Discharging without Charging Station J23500-01
NOTICE: Do not use alcohol to remove moisture

fro m th e s y s te m . A lc o h o l can d a m a g e
components.

GAGE CALIBRATION
Before evacuation, check the low pressure gage for
p ro p e r c a lib ra tio n and vacuum system fo r p ro p e r
o p e ra tio n . W ith th e g a g e d is c o n n e c te d from the
refrigeration system, be sure that the pointer indicates to
the center of 0. Tap the gage to be sure the pointer is
not sticking. If necessary, calibrate as follows:
Remove the cover from the gage.
Holding the gage pointer adjusting screw with
one hand, carefully force the pointer in the
proper direction to position the pointer at the
0 position. Tap the gage to be sure the
pointer is not sticking. Replace the gage cover.
VACUUM SYSTEM CHECK

Before connecting the vacuum pump to the A/C system
run the pump connected to the low pressure gage to
determine the vacuum pump capability. If the vacuum
system is unable to reach 711.2 - 736.6 mm (28 to 29
inches) or more vacuum check for leaks. If no leaks are
found check the vacuum pump.
CHARGING STATION METHOD

Follow the J-23500-01 Charging Station instructions.
Use with the following exceptions:
1. Do not connect the high pressure line to the air
conditioning system.
2. Keep the high pressure valve on the charging
station closed.
3. P erform th e e vacu ate and ch arge p ro c e d u re
through the accum ulator low side pressure service
fitting.
4. Following these procedures will prevent high side
pressure from dam aging the charging station if an
error is made during the sequence.
DISPOSABLE CAN OR
MULTI-CAN METHOD
Tools Required:
J-6271-01 Single Can Refrigerant Dispensing Valve
J-6272-02 Four Can Refrigerant Dispensing Valve
1. Use tool J-6271-01 for single can or m ulti-can
dispensing unit.
2. Use tool J-6272-02 multi-can open valve. When
using disposable cans, close the tapping valve and
then attach the can(s) following the instructions
included with the tapping valve or tapping manifold
adapter.
REFRIGERANT DRUM METHOD

Tool required:
J-23390 Refrigerant Dispensing Valve
1. Use tool J-23390 for a 5.443 kg (12 lb.) can. A 13.608
kg (30 lb.) can has a built in opener-valve. Place the
drum on a scale and note weight before charging.
During charging, watch the scale to determine the
amount used.
Im portant
C lo s e th e o u tle t v a lv e on th e o p e n e r
(clockwise) before installing the opener to the
R-12 container.
To evacuate the A/C system install Manifold
Gage Set and Vacuum Pump.
SLOWLY open high and low side gage
v a lv e s a nd b e g in v a c u u m p u m p
operation. Pump the system until the low
side gage reaches 459 - 475 mm (28 to
29 inches of mercury [vacuum]) or more.
The evacuation procedure will specify 459 475 mm (28 to 29 inches) of mercury at sea
level. For each 304.8 mm (1,000 ft.) above sea
level, lower the specification by one inch of
vacuum. At 1524 mm (5,000) feet elevation
only 376.9 mm (23 to 24 inches) of vacuum is
required.
If the prescribed m ercury (vacuum) cannot be
reached, close the vacuum control valve, shut
off the pum p and look for a leak at the
connections or the pump.
2. When the gage reaches the prescribed vacuum, the
system is evacuated. Close the high side gage set
valve and turn OFF the vacuum pump.
3. Watch the low side gage to be sure vacuum holds
for five minutes. If the vacuum holds, disconnect the
vacuum hose at the gage set and then proceed to
charging.
4. If the vacuum does not hold for five minutes, charge
the system with 0.227 kg. (8 ounces) Refrigerant-12
and leak check. Discharge the system again and
repair any leaks. Repeat the evacuation procedure.
CHARGING THE SYSTEM

1. Start the engine, run with the choke open and the
fast idle speed reduced to normal idle, set the A/C
control lever on OFF.
2. W ith the drum or 0.397 kg (14 ounces) can(s)
inverted, open source valve(s) and allow 0.454 Kg
(one (1) pound) or more 0.397 kg (14 ounces) can of
liquid Refrigerant-12 to enter the system through low
side service fitting on accumulator.
3. When one 0.454 Kg (1 pound) or one 0.397 kg (14
ounces) can of liquid Refrigerant-12 enters the
system, engage the compressor by setting the A/C
control lever to NORM and blower speed on HI to
draw in the remainder of the charge.
To speed Up the operation, use a fan to pass air over
the condenser. If the condenser temperature remains
below the charging cylinder temperature, Refrigerant-12
will enter the system faster.
4. Shut off the source valve and run the engine for 30
seconds to clear lines and gages.
5. With the engine running, remove the charging low
side hose adapter from the accum ulator service
fitting. Unscrew rapidly to prevent Refrigerant-12
from escaping.

CAUTION: Never remove a gage line from its
adapter when the line is connected to the A/C
system. Always remove the line adapter from
the service fitting to disconnect a line. Do NOT
remove the charging hose at the gage set while
it is attached to the accumulator. This will
discharge the system because of the depressed
schrader valve in service low side fitting. Also,
th e e sc a p in g R e frig e ra n t-1 2 may cause
personal injury.
6. Replace the protective cap on the accum ulator
fitting.
7. Turn the engine off.
8. Leak the check system with a J-6084 Leak Detector.
9. Start the engine.
10. With the system charged and leak-checked, operate
the system and test for pressures as outlined under
R e la tive H um idity, T em p eratu re and P ressure
Relationship of Refrigerant-12 (figure 10).
ACCUMULATOR ASSEMBLY
The accum ulator assem bly has a service replacement
which includes two seals (o-rings for the inlet and outlet
connections). The desiccant is NOT serviced separately it is part of the sealed accum ulator assembly. Refer to
CCOT Refrigerant Oil and Distribution for presence of
refrigerant oil and service conditions when removing the
accum ulator from the vehicle to measure the oil.
Replace the accum ulator assembly when:
1. A physical perforation prduces a leak.
2. The (o rifice ) screen e xpe rie nce s co n tin u e d or
repeated plugging.
3. An evaporator fails because of inside-out internal
corrosion.
DO NOT REPLACE the accum ula tor assem bly
where:
1. A dent is found in the outer shell of the accumulator.
2. A vehicle is involved in a collision and there is no
perforation to the accum ulator. Cap or place a
plastic bag around an open refrigerant line.
SPECIFIC COMPONENT DIAGNOSIS

COMPRESSOR
Com pressor defects can appear as noise, seizures,
leakage or low discharge pressures.
N O TIC E: R esonant c o m p res so r noises are
normal; however, irregular noise or rattles may
indicate broken parts or wear. To check seizure,
de-energize the magnetic clutch and rotate the
d riv e p la te . If ro ta tio n is im p o s s ib le the
compressor is seized.
To ch eck for a leak, refer to Leak Testing The
Refrigerant System. A faulty internal seal, a restriction or
an in s u ffic ie n t re frig e ra n t ch arge can cause a low
discharge pressure. Check before servicing.
1. Valve stuck open.

Noisy compressor.
No cooling - freeze up.
2. Valve stu ck c lo se d , broken pow er e le m e n t or
plugged screen.
Very low suction pressure.
- No cooling.
3. Poorly located power element bulb.
Normal pressure.
Poor cooling.
DIAGNOSIS FOR MALFUNCTIONING VALVE
CONDENSER
A condenser may leak or be restricted. A restriction will
cause excessive compressor discharge pressure. If a
partial restriction is present, ice or frost will form after the
restriction as the refrigerant expands after passing
through the restriction.
Air flow restrictions through the condenser or radiator
can cause high discharge pressures. During normal
condenser operation, the outlet pipe will be cooler than
the inlet pipe.
EXPANSION VALVE
There are five expansion valve malfunctions: valve
stuck open, valve stuck closed, broken power element, a
restricted screen or an improperly located or installed
power element bulb. To correct the first three conditions,
replace the valve; to correct the last two, replace the valve
inlet screen and properly install a power element bulb.
Operating the system will indicate valve trouble.
U se th e fo llo w in g
malfunctioning valve.
p ro c e d u re
to
d e te rm in e
1. Operate the system at normal idle. If the valve is

m a lfu n c tio n in g , th e low p re s s u re re a d in g s
(evaporator pressure) will be above specifications
(figure 10).
2. The loss of system performance is not as evident
when the compressor head pressure is below 1379
kPa (200 psi). Increase the system head pressure by
partially blocking the condenser. Disconnect the
b lo w e r lead w ire and o p e ra te th e syste m to
d e te rm in e if th e e v a p o ra to r p re ssu re can be
obtained.
EVAPORATOR
An inade qu a te su p p ly of cool air can cause the
evaporator to m alfunction. Check for a plugged core, a
cracked case or a leaking seal.

REFRIGERANT LINE
RESTRICTIONS
There are three refrigerant line restrictions:
1. Suction Line - A restriction will cause low suction
pressure at the compressor, low discharge pressure
and little or no cooling.
2. D isch a rg e Lin e - A re s tric tio n w ill ca use the
pressure relief valve to open.
3. Liquid Line - A restriction will be caused by low
discharge and suction pressure, and insufficient
cooling.
REFRIGERANT-11 FLUSHING
PROCEDURE
Tool Required:
J-33883 Air Conditioning Flushing Kit
Flush the system when:
1. A compressor has failed resulting in debris in the air
conditioning system refrigerant components or oil.
2. Inspection of the orifice tube shows the inlet screen
to be 25% or more coated with debris.
3. Refrigerant oil is overcharged or contaminated.
Follow the kits instructions and flush each component
separately allowing the Refrigerant-11 to soak in each
component for five minutes.
Flushing the system requires approximately 6.804 kg
(15 lbs.) of R-11 and 1.814 (4 lbs.) of R-12 and up to 0.312
kg (11 oz.) of 525 viscosity refrigerant oil. The actual
quantities of R-11, R-12 and oil depends on the system,
the number of components flushed and the amount of
debris in each component.
Remove Refrigerant-11 by purging each components
with Refrigerant-12 followed by a system evacuation.
Refer to On-Vehicle Service for removal procedures
for the system s com ponents. Cap or plug all open
connections when removing the components.

1.
2.
3.
4.
5.
6.

Refrigerant from the system.
Compressor.
Accumulator.
Orifice tube.
Evaporator.
Inspect
Each com ponent for wear or damage. Replace if
necessary.
Clean
Flush each component with J-38833. Follow the
directions included with the kit.
+ 4- Install or Connect (Figure 24)
1.
2.
3.
4.
5.
Evaporator.
Orifice tube.
Accumulator.
Compressor.
Refrigerant-12 to the system.
Evacuate, charge and test the system.
Figure 24Flushing a Component with J-33883

Refer to Specifications for Refrigerant-12
and 525 viscosity refrigerant oil.
ON VEHICLE SERVICE
35 N-m (26 Ft. Lbs.)
3. Connector attaching bolt.

4. Connector.
Cap or plug open connections.
5. Electrical lead to the clutch acutuating coil.
6. Bolt.
Loosen the bracket and pivot bolts.
7. Compressor.
Drain and measure the oil.
Check for contamination.
|-n-| Install or Connect (Figures 25, 26, 27 and 28)

1. Oil to the compressor.
1. H o se A s s e m b ly
2. B o lt
7. C o m p re s s o r
F-02554
Figure 25Hose Plate and Bolt Removal Typical
COMPRESSOR REPLACEMENT
(R/V)
|<-+| Remove or Disconnect (Figures 25, 26, 27 and
28)
1. Battery negative cable.
2. Refrigerant from the system.
| ? | Im portant
Replace with fresh oil. If the system was
s e rv ic e d , in s ta ll a fu ll, fre s h c h a rg e of
refrigeration oil.
2. Compressor.
Position to the m ounting bracket.
3. Nuts, bolts and spring washer.
4. Connector assembly to the rear of the compressor.
Im portant
Use new seals (o-rings) coated with clean
refrigeration oil.
5. Electrical lead to the coil.
6. Com pressor belt.
Figure 26R/V Compressor Installation 4.3L, 5.0L, 5.7L Engines
Figure 27R/V Compressor Installation 6.2L Engine

Adjust
Belt. Refer to ENGINE COOLING (SEC. 6B1).
8. Evacuate, charge and check the system.
COMPRESSOR REPLACEMENT (G)

++ Remove or Disconnect (Figures 29, 30 and 31)
2. Compressor clutch connector.
4. Belt.
Loosen the three bolts that hold the idler
pulley to the air conditioning support bracket.
Refer to ENGINE COOLING (SEC. 6B1).
Back off the idler pulley adjustment screw.
5. Engine cover.
6. Air cleaner.
7. Fitting and m uffler assembly.
Cap or plug all open connections.
8. Compressor bracket.
9. Engine oil tube support bracket bolt and nut.
10. Clutch ground lead.
11. Compressor.
Im portant
D ra in and m e a s u re th e o il. C h e c k fo r
contamination.
|+ + | Install or Connect (Figures 29, 30, and 31)

1. Oil to the compressor.
Im portant
Replace with fresh oil. If the system was
s e rv ic e d , in s ta ll a fu ll, fre s h c h a rg e of
refrigeration oil.
2. Compressor.
Position to the mounting bracket.
3. Nuts, bolts and spring washer.
4. Connector assembly to the rear of the compressor.
Im portant
refrigerant oil.
5. Electrical lead to the coil.
6. Compressor belt.
A djust
Tighten the idler pulley adjustm ent screw.
Measure the belt tention with J-23600-B. Refer
to ENGINE COOLING (SEC. 6B1).
Tighten the three bolts that hold the idler
p u lle y b ra c k e t to th e a ir c o n d itio n in g
compressor support bracket.
Tighten
Bolts to 33 N m (24 ft. lbs.).
R echeck the belt tension w ith J-23600-B.
8. Refrigerant to the system.
Evacuate, charge and leak test.
C-K Series Compressor Mounting Component View

V8 (7.4 Liter) Gas Engine - Federal Emissions
C-K Series Compressor M ounting Component View

V8 (7.4 Liter) Gas Engine - California Emissions
F-00159
Figure 28R/V Compressor Installation 7.4L Engine
5.0L and 5.7L Engines
4.3L Engine
7.
C o m p re s s o r
25. B e lt
B-07680
Figure 29G-Compressor installation 4.3L, 5.0L and 5.7L Engines (Serpentine Drive)
Figure 31G-Compressor Installation 6.2L Engine
A/C SYSTEMR/V SERIES
1. B lo w e r/E v a p o ra to r A s s e m b ly
2 . R e s is to r
3. S cre w
4. S cre w
5. A u x ilia ry R e s is to r
6. H ose C o n n e c to r
8. U p p e r R e ta in e r
9. S cre w
10. L o w e r R e ta in e r
11. C o n d e n s e r
12.
13.
14.
15.
16.
17.
18.
19.
20.
Seal
A c c u m u la to r
R e frig e ra n t Lin e
C ap
R elay
B o lt
B lo w e r M o to r
G ro u n d W ire
W irin g H a rn e s s
B-08670
Figure 32Air Conditioning System Component View R/V
CONDENSER REPLACEMENT
3. Grille assembly.
4. Radiator grille center support.
5. Left g rille su pp ort to upper fender support (2)
screws.
6. Condenser inlet and outlet lines, and the outlet tube
at the right end of the condenser (figure 32).
Im portant
7. Condenser to radiator support screws (figure 33).
8. Bend the le ft g rille su pp ort outb oa rd to gain
clearance for condenser removal.
9. Condenser assembly by pulling it forward and then

lowering it from the vehicle.
-<- Install or Connect (Figures 32 and 33)

1. New condenser.
Im portant
Add 30 ml (1 ounce) of clean refrigeration oil to
a, new condenser.
2. Left grille support.
3. Radiator support screws.
4. Condenser inlet and outlet lines.
Im portant
Use new seals (o-rings) coated with clear
re frig e ra tio n w hen co n n e c tin g re frig e ra n t
lines.
Left grille support to the upper fender support
screws.

8. U pper retainer 11. C ondenser
10. Lower retainer
4. Inlet and outlet lines (97).
Im portant
5. Bracket screws.
6. Accum ulator (13) (figure 34).
Im portant
Drain excess re frig e ra n t oil into a clean
container. Measure and add new oil.
"+ Install or Connect (Figures 32 and 34)

1. New accumulator.
Im portant
Figure 33Conderser Replacement

6. Radiator center support.
7. Grille assembly.
ACCUMULATOR REPLACEMENT
2.
3.
4.
5.
6.
Add 0.028 kg. (one ounce) of clean refrigerant

oil. PLUS an amount equal to that drained.
Bracket screws.
Inlet and outlet lines.
Compressor clutch connector.
Evacuate, charge and check the system.
BLOWER ASSEMBLY
REPLACEMENT
Remove or Disconnect (Figures 32, 34 and 35)
2. Insulator - Diesel Engine (figure 35).
3. Blower motor lead and ground wires (134).

2. Com pressor clutch connector.
105. Relay
13. A c c u m u la to r
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
18.
133.
134.
135.
136.
137.
3.
139.
140.
S crew
G ro m m e t
C ase
G ro m m e t
C ore
C la m p
S cre w
R ivet
B ra cke t
P late
O rific e
G a ske t
B lo w e r M o to r
H o se
S w itc h A s s e m b ly
C ase
Seal
R e s is to r
C la m p
S w itc h
105
139
126
F-02557
Figure 34Evaporator and Blower Assembly

5.
6.
7.
8.
Evaporator case cover.

Nuts to the studs that project into the dash panel.
Evacuate, charge and check the system.
ORIFICE (EXPANSION TUBE)

REPLACEMENT
The expansion tube is located in the evaporator core
inlet line.

1. Discharge the system.
2. Condenser to the evaporator line at the evaporator
inlet (figure 35.)
Cap or plug the open line.
3. Expansion tube from the evaporator core inlet line.
Use needle-nose pliers to remove the core.
4. Expansion tube seal (o-ring) from the core inlet line.
4. Blower motor cooling tube.
5. Blower assembly.
Case attaching screws.
Carefully pry the blower flange away from the
case if the sealer acts as an adhesive.
6. Blower wheel from motor shaft.
Remove shaft nut.
Install or Connect (Figures 32, 34 and 35)

1. Blower wheel to the motor shaft.
2. Blower assembly.
Use a new bead of sealer on the flange.
3. Blower assembly.
4. Blower motor cooling tube.
5. Blower motor lead and ground wires.
EVAPORATOR CORE
REPLACEMENT
3. Nuts from the selector duct studs projecting through
the dash panel.
4. Evaporator case cover (122).
5. Inlet and outlet lines.
Cap or inlet open connections.
6. Expansion tube. Refer to Orifice (Expansion Tube)
R eplacem ent.
7. Evaporator core assembly.

1. New core.
Add 90 ml (3 ounces) of clean refrigeration oil.
2. Expansion tube.
refrigeration oil.
4. Bead of sealer to cover.
Remove old sealer before applying new bead
of sealer.
|-n-| Install or Connect (Figures 4 and 35)

1. Expansion tube seal (o-ring) to the core inlet line.
Use new seal (o-ring) coated w ith clean
refrieration oil.
Insert the short screen and end of the orifice
into the evaporator inlet line.
2. Expansion tube to the evaporator core inlet line.
inlet.
SELECTOR DUCT AND HEATER

CORE REPLACEMENT
++ Remove or Disconnect (Figures 36 and 37)
2. Drain the radiator.
3. Heater hoses from the core tubes (148) (figure 36).
Plug the core tubes to prevent spillage.
4. Instrument panel com partm ent and door.
5. Center duct to the selector duct (200) (figure 37).
6. Center lower and center upper ducts.
7. Temperature door cable.
8. Nuts from the three selector duct studs that project
into the dash panel.
9. Selector duct to dash panel screw (inside the
vehicle).
10. Selector duct assembly.
Pull rearward until the core tubes clear the
dash panel.
Lower the selector assem bly to reach the
vacuum and electrical harness.
11. Vacuum and electrical harness.
12. Selector duct assembly.
13. Core mounting strap screws.
14. Core.

1.
2.
3.
4.
Core.
Core mounting strap screws.
Selector duct assembly.
Vacuum and electrical harnesses.
J47 148
53.
145.
146.
147.
148.
149.
150.
151.
152.
153.
Actuator
Valve
Housing
Screw
Core
Strap
Screw
Clamp
Connector
Link
154.
155.
156.
157.
158.
159.
160.
161.
162.
Connector
Screw
Bracket
Shaft
Spacer
Spring
Shaft
Bracket
Case
163.
164.
166.
167.
168.
169.
170.
171.
Valve
Nut
Valve
Screw
Link
Pin
Seal
Valve
172.
173.
174.
175.
176.
177.
149
Connector
Plate
Grommet
Hose
Screw
Yoke
F-00093
Figure 36Air Conditioning and Heater Component View

5.
6.
7.
8.
9.
10.
11.
12.
4.
5.
6.
7.
Selector duct assembly.

Temperature door cable.
Center lower and center upper ducts.
Center duct to selector duct.
Instrum ent panel bar and door.
Heater hoses.
Adjust
T e m p e ra tu re
door
c a b le .
R e fe r
Temperature Door Cable A djustm ent.
Cam to actuator arm screw (213).

Actuator and bracket from the cam.
Actuator to bracket nuts.
Actuator from the bracket (53).
to
ACTUATOR-PLENUM SIDE
VENT REPLACEMENT
1. Vacuum hose at the actuator.
2. Valve return spring at the actuator end (216) (figure
38).
3. Actuator bracket m ounting screws.
1.
2.
3.
4.
5.
6.
7.
Actuator to the bracket (53).

Bracket nuts.
Actuator and bracket to the cam (211).
Cam to the actuator arm screw.
Actuator bracket m ounting screws.
Valve return spring at the actuator end (216).
Vacuum hose to the actuator.
PLENUM VALVE REPLACEMENT

1. Raise the hood.
2. Cowl plastic grille.
3. Three cowl to valve assembly screws (226) (figure
39).
196
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
A d a p te r
S cre w
A d a p te r
H ose
D u c t A s s e m b ly
S crew
Seal
Seal
G a ske t
S cre w
193.
194.
195.
196.
197.
198.
199.
200.
201.
202.
203.
204.
R e ta in e r
A d a p te r
F elt
D e fle c to r
O u tle t
A ir C o n d itio n in g A s s e m b ly
B o lt
O u tle t A s s e m b ly
S cre w
D e fle c to r
D e fle c to r
F-00080
Figure 37Duct Assembly Component View
Figure 38Actuator-Plenum Side Vent

Valve assembly from the vehicle.
4. Actuator arm pushnut.
5. Actuator to valve nuts.
Separate the valve and actuator.
"+ Install or Connect (Figure 39)

1.
2.
3.
4.
5.
Actuator to valve nuts.

Actuator arm push nut (53).
Valve assem bly to the vehicle.
Cowl plastic grille.
Close the hood.
CONTROL ASSEMBLY
REPLACEMENT
1.
2.
3.
4.

Radio. Refer to RADIO (SEC. 9A).
Instrum ent panel bezel.
Control from the dash.
Lower the control to gain access to the control

assembly.
Im portant
Do not kink the cable.
5. Cable (236) (figure 40).
6. Vacuum harness.
7. Electrical harness.
8. Control.
-<- Install or Connect (Figure 40)

1. Blower switch to the new control.
3. Vacuum harness.
4. Cable (236).
5. Control to the dash.
7. Radio. Refer to RADIO (SEC. 9A).

3. Place the temperature lever in full COLD position
and hold while tightening the cable attaching screw.
4. Install instrument panel com partm ent and door.
BLOWER SWITCH
REPLACEMENT
The blower switch is located on the rear of the control
assembly.

2. Instrum ent panel bezel.
3. Control to instrument panel screws.
Set the control on top of the radio.
4. Switch to control screws.
6. Vacuum harness at the master switch.
7. Switch (235).

1. Switch (235).
2. Vacuum harness.
4. Switch to control screws.
5. Control to the instrum ent panel.
6. Instrum ent panel bezel.
TEMPERATURE DOOR
CABLE ADJUSTMENT
Adjust (Figure 41)
1. Remove instrument panel com partm ent and door.
2. Loosen the cable attaching screw at the selector
duct assembly.
Make sure the cable is installed in the bracket
on the selector duct assembly.
Figure 40Control Assembly Replacement
240
241 244
VIEW B
240.
241.
242.
243.
244.
Cable-Temperature Control
Bolt/Screw
Retainer
Heater Control Assem bly
Cam
VIEW A
F-02766
Figure 41Temperature Door Cable Adjustment
VACUUM TANK REPLACEMENT

The vacuum tank is mounted to the cowl behind the left
front fender.

1. Vacuum lines at the tank.
2. Tank to dash panel screws.
3. Tank (251).

1. Tank (251).
2. Vacuum hoses.
BLOWER MOTOR
The blower motor resistor is located in the blower side
of the blower-evaporator case.
|+ + | Remove or Disconnect (Figure 32)

1. W iring harness at the resistor.
2. Resistor to case attaching screws.
3. Resistor (81).
I++I Install or Connect (Figure 32)

1. Resistor (81).
2. Screws.
3. W iring harness.
BLOWER MOTOR RELAY

REPLACEMENT
The blower motor relay is located on the blower side of
the blower-evaporator case.

1. W iring harness at the relay.
2. Attaching screws.
3. Relay (105).

1. Relay (105).
2. Mounting screws.
3. W iring harness.
C 60
7. V a cuu m C o n tro l H o se
F-00222
Figure 43Vacuum Hose 5.0, 5.7 and 7.4L Engine
Figure 44Vacuum Hose 6.2L Engine

FUSE REPLACEMENT
A 25-amp fuse, located in the junction block, projects
the system except for the blower circuit. The fuse for the
blower circuit is located in the electrical wiring between
the junction block and the blower relay.
VACUUM LINE REPLACEMENT

ENGINE COMPARTMENT
Rubber vacuum hoses can be repaired by cutting the
hose at a leak, inserting a connector and pushing the
hoses onto the connector.
If the entire hose needs replacing, pull the hose from
each connector and thread a new hose into place. Follow
the routing of the original hose.
For vacuum line routing, refer to figures 42, 43 and 44.
1. 4.3L engine (figure 42).
2. 5.0L, 5.7L and 7.4L engines (figure 43).
3. 6.2L engine (figure 44).
REFRIGERANT-12 HOSE
REPLACEMENT
Refrigerant hoses are replaced as a unit. The hose
assembly must be removed from the compressor and the
condenser.
The hose assem bly has captured seals (o-rings)
which are not replaced. New seals are installed on the
new hose assembly. For installation, refer to figures 46, 47
and 48.
|<-| Remove or Disconnect (Figures 46, 47 and 48)

2. Hose plate and bolt from the rear of the compressor
(275).
3. Hose connections (97) at the condenser (70) and the
accum ulator (107).

1. Hose connections (97) at the condenser (70).
VACUUM LINE
REPLACEMENT DASH
These lines are m olded to a connector w hich is
attached to a vacuum control switch on the control
assembly.
Repair a leaking vacuum hose by cutting the hose at
the leak, inserting a connector and pushing the hoses
onto the connector.
If an entire hose needs replacing, cut the hose off at the
connector and attach the hose to the control assembly
vacuum switch.
To fin d the dash vacuum h a rn e ss and a c tu a to r
installation, refer to figure 45.
Tighten
Fittings to 24 N m (18 ft. lbs.).
2. Hose connection (97) at the accum ulator (107).
Tighten
3. Hose plate and bolt to the rear of the compressor
(275).
Tighten
Bolt to 34 N-m (25 ft. lbs.).
4. Refrigerant to the system.
Leak test.
7. V a cuu m H a rn e s s
53. A c tu a to r
E. V a cu u m L in e G ray To S o u rce
F. V a cu u m L in e O ran ge
G. V a cuu m L in e S trip e
236. C ab le
244. Cam
265- C o n tro l A s s e m b ly
266.
267.
P le n u m Valve (A ctu a to r)
R e c irc A ir Valve (A ctu a to r)
268. H e a te r A s s e m b ly
269. A ir C o n d . Valve (A ctu ator)
270. D e fro s t (A ctu a to r)
H. V a cu u m L in e D ark B lue
I. V a cu u m L in e Tan
F-00234
Figure 45Vacuum Control Hose Dash
Figure 46R/V 4.3L Engine Refrigerant Hose Assembly
Figure 48R/V 6.2L Engine Refrigerant Hose Assembly
REAR INTERIOR ROOF MOUNTED SYSTEMSUBURBAN

303
301.
302.
303.
304.
305.
W a sh e r
S crew
S h rou d
S crew
C lip
306.
307.
308.
309.
310.
D e fle c to r
O u tle t
B ra cke t
N ut
S crew
F-00224
Figure 49Rear Interior Roof Mounted System Shroud

The rear interior roof mounted system is used with the
front air conditioning system. Refer to figures 49, 50 and
51.

1. Duct (303).
2. Screws and brackets.
REAR DUCT
REPLACEMENT
T his d uct covers the b lo w er-evaporator a ssem bly
located at the rear of the vehicle. It has four adjustable air
outlets (figure 49).

1. Drain tube from the rear duct.
2. Screws securing the duct to the roof panel and rear
header brackets.
3. Duct (303).
3. Drain tube.
BLOWER MOTOR RESISTOR

REPLACEMENT
The blower motor resistor is located on the cover side of
the blower-evaporator. To remove, refer to Blower Motor
Resistor, A/C System R/V Series.
320.
321.
322.
323.
324.
325.
326.
327.
328.
329.
330.
331.
332.
S crew
B ra cke t
S crew
S crew
S u p p o rt
S cre w
C ase
Plate
S crew
Seal
M o to r A sm .
E yelet
T erm inal
333.
334.
335.
336.
337.
338.
339.
340.
341.
342.
343.
344.
B ra cket
S crew
Seal
Case
C lip
Seal
C ore A sm .
Seal (O -ring)
R e frig e ra n t L in e s
Valve A sm .
S crew
C la m p s
F-00602
Figure 50Rear Interior Roof Mounted Evaporator and Blower Component View
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
S crew
B ra cket
Seal
Seal
C lip
B o lt
C lip
W ire
B ra cket
C over
B ra cket
S crew
B ra cket
H ose
H ose
C lip
C lip
B o lt
W a sh er
F ittin g
26. L o w e r R e ta in e r
27.
29.
34.
35.
36.
37.
38.
41.
42.
44.
Seal
P late
C lip
S cre w
B ra cke t
45.
46.
47.
48.
49.
303.
324.
E va p o ra to r and B lo w e r A s s e m b ly
D e fle c to r
O u tle t
C la m p
Tube
S h ro u d
S u p p o rt
F-00667
Figure 51Rear Interior Roof Mounted Evaporator Hoses Component View

BLOWER MOTOR ASSEMBLY
REPLACEMENT
++
1.
2.
3.
4.
5.
6.

Rear duct (303).
Blower motor ground strap.
Blower motor lead wire.
Lower to upper blower-evaporator case screws.
Case and motor assembly (326) (336).
n- Install or Connect (Figures 50 and 51).

1. New expansion valve assembly (342).
Remove caps or plug.
refrigeration oil.
2. Sensing bulb.
3. Lower case and blower motor assembly.
4. Blower motor lead.
5. Ground wires.
6. Rear duct.
Important
Before removing the case screws, support the
lower case to prevent damage to the case or
motor assembly.
7. Motor retaining strap.
8. Motor and wheels (330).
9. Wheels from the motor shaft.

1. W heels to the motor shaft (330).
I. Place the tension springs on the wheel hubs.
2. Motor and wheels to the case.
Align the wheels to prevent contact with the
case.
3. Motor retaining strap and foam.
4. Lower case and blower motor assem bly in the
vehicle (336).
5. Lower to upper case screws.
Turn the blower wheels to prevent rubbing
against the case.
6. Center ground strap.
7. Blower lead wire.
8. Rear duct.
EXPANSION VALVE
REPLACEMENT
This system incorporates an expansion valve which
does not utilize and external equalizer line.

1.
2.
3.
4.
5.
6.

Purge the system of refrigerant.
Rear duct.
Blower motor lead.
Ground wire.
Lower to upper blower-evaporator case screws.
Im portant
Before removing the case screws, support the
lower case and motor assemblies to prevent
damage to the case or motor assembly.
Lower case and motor assembly (336).
Expansion valve sensing bulb clamps.
Valve inlet and outlet lines.
Cap or plug open lines.
10. Expansion valve assembly (342).
EVAPORATOR CORE
REPLACEMENT
++
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Purge the system of refrigerant.
Rear duct.
Blower motor lead.
Ground wire.
Refrigerant lines at the rear of the blower-evaporator
assembly (351).
Cap or plug the open connections.
Blower-evaporator support to roof rail screws.
Blower-evaporator (339).
Place the blower-evaporator upside down on a
work bench.
Lower case assembly.
Upper case from the evaporator core.
Expansion valve inlet and outlet lines.
Expansion valve capillary bulb from the evaporator
oulet line.
Valve.
Plastic pins that hold the screen to the core.
Screen.

1. Wire screen to the front of the core.
2. Plastic pins.
3. Expansion valve inlet and outlet lines (341).
rerfrigeration oil.
4. Sensing bulb to the evaporator outlet line (342).
Bulb must make good contact with the line.
Add 30 ml (3 ounces) of clean refrigeration oil
to new core.
5. Upper case and supports to the core.
6. Lower core case and blower assembly.
7. Blower-evaporator assembly to the roof.
8. Support to roof rail screws.
9. Refrigerant lines to the blower-evaporator unit.
U se new s e a ls (o -rin g s ) w ith c le a n
refrigeration oil.
10. Blower lead wire.
11. Ground wire.
12. Rear duct.

BLOWER MOTOR SWITCH
REPLACEMENT
The a u xilia ry heater and air c o n d itio n in g blow er
switches are located to the right of the steering wheel.
1.
2.
3.
4.

Switch retaining screws.
Wiring harness.
Switch.
4-
1.
2.
3.
4.
Switch.
Wiring harness.
Switch retaining screws.
1.
2.
3.
4.
FUSE REPLACEMENT
S crew
N ut
Bezel
S w itc h
F-02555
Figure 52Blower Switch Replacement
A-25 amp fuse at the junction box protects this system.

A 20-amp fuse, located between the junction block and
the rear blower motor switch, protects the rear blower high
speed circuit.
A/C SYSTEM G SERIES

CONDENSER REPLACEMENT
ACCUMULATOR
REPLACEMENT
Remove or Disconnect (Figure 53 and 54)

3. Grille, hood lock, and center hood lock support.
4. Condenser inlet and outlet lines at the condenser
(70).
1.
2.
3.
4.

Com pressor clutch cable.
Discharge the system.
Inlet and outlet lines.
5. Screws attaching the left side condenser bracket to

the radiator.
6. Screws attaching the right side condenser bracket
to the condenser.
7. Condenser.
Im portant
5. Bracket screws.
6. Accumulator.
8. Left bracket from the condenser.
|-K-| Install or Connect (Figure 53)
I 2 I Im portant
D rain excess re frig e ra n t oil into a clean
container. Measure and record amount. Use
fresh oil.
1. Left bracket to condenser.

2. Condenser (70).
Add 30 ml (1 ounce) of clean refrigeration oil to
a new condenser.
3. Screws attaching the left side of the condenser
bracket to the condenser.
4. Screws attaching the right side of the condenser
bracket to the condenser.
5. Condenser inlet and outlet lines at the condenser
(70).
Install or Connect (Figure 53 and 54)

New accumulator.
Im portant
Add 30 ml (1 ounce) of clean refrigerant oil
PLUS an amount equal to that drained.
2. Bracket screws.
6. Grille, hood lock and center hood lock support.
7. Refrigerant.
4. Compressor clutch connector.
9. Evacuate, charge and test the system.
20
12
1.
2.
3.
6.
7.
B lo w e r and E va p o ra to r A s s e m b ly
S crew
R e s is to r
H ose C o n n e c to r
C ondenser
12.
13.
14.
15.
16.
Seal
A c c u m u la to r
R e frig e ra n t Line
Cap
R elay
31.
32.
33.
B-08467
Figure 53Air Conditioning System Component View
HEATER CORE
REPLACEMENT
" Remove or Disconnect (Figure 54)
2 . Engine cover.
3. Steering column to instrument panel.
Lower column.
4. Upper and lower instrument panel attaching screws
and radio support bracket attaching screw.
5. Raise and support right side of the instrum ent
panel.
6. Right lower instrum ent panel support bracket.
7. Recirculating air door vacuum actuator.
8. Tem perature cable and vacuum hoses at the
distributor case.
9. Heater distributor duct.
10. D efroster duct to dash panel attaching screws
(below the windshield).
11. Heater hoses (457).
Plug to prevent spillage.

12. Three nuts from the bolts that hold the heater core
case to the dash panel and one screw at the lower
right corner (inside).
13. Distributor assembly from the vehicle.
14. Gasket to expose the screws attaching the case
sections together.
15. Temperature cable support bracket.
16. Case attaching screws and separate the case.
17. Heater core (457).

1.
2.
3.
4.
5.
6.
7.
8.
9.
New heater core.

Screws and case.
Temperature cable support bracket.
Gasket.
Distributor assembly.
Heater core nuts to bolts.
Heater hoses.
Defroster duct to dash panel screws.
Heater distributor duct.
425.
53.
427.
428.
429.
430.
431.
432.
433.
434.
435.
436.
437.
438.
439.
N ut
A c tu a to r A s s e m b ly
Case
Valve
N ut
Fan A s s e m b ly
W a sh er
T erm in al
M o to r A s s e m b ly
Tube
A c c u m u la to r ^ ^
D e h y d ra to r j [
A s s e m b ly
C la m p
if
.
C la m p
C la m p
Case
445.
446.
447.
448.
449.
A s s e m b ly 4 5 5
Case
Seal
Seal
C la m p ^ ^ ^ ^
E v a p o ra to r
A s s e m b ly
Seal
F ilte r
R e ta in e r
S w itc h A s s e m b ly .
C ase
"*
450.
451.
452.
453.
454.
455.
O rific e
G a sket
G a ske t
B ra cke t
G a ske t
S tud
440.
441.
442.
443.
444.
456.
457.
458.
459.
460.
461.
462.
463.
464.
465.
466.
467.
468.
470.
471.
472.
473.
474.
475.
Valve A s s e m b ly
C ore
C la m p
Valve
S h a ft
C o n n e c to r
L in k
C o n n e c to r
S h a ft
C ase
D uct
H o u s in g
R e ta in e r
D uct
Seal
Valve
S h a ft A s s e m b ly
460461
F-02408
Figure 54Evaporator Blower Component View

10. Tem perature cable and vacuum
distributor.
hoses at the
EVAPORATOR CORE
(W/DIESEL) REPLACEMENT
11. Right lower instrum ent panel support bracket.
12. Right side of the instrum ent panel.

13. Upper and lower instrum ent panel screws.
14. Radio support bracket screw.
15. Steering column to instrum ent panel attaching bolts
and raise the column.
16. Engine cover.
ORIFICE (EXPANSION TUBE)

REPLACEMENT
The orifice tube is located in the evaporator core inlet
line.

inlet.
Cap or plug the open line.
3. Expansion tube from the evaporator core inlet line.
Use a needle nose pliers to remove the orifice
from the tube.
4. Expansion tube seal (o-ring) from the core inlet line.
-+ Install or Connect (Figure 53)
1. Cold air intake.

2. Hood latch assembly and cable retainer and place it
out of the way.
3. W indshield solvent tank.
Im portant
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1. Expansion tube seal (o-ring) to the core inlet line.

Use a new seal (o-ring) coated with clean
refrigeration oil.
Insert the short screen end of the orifice into
the evaporator inlet line.
2. Expansion tube to the evaporator core inlet line.
inlet.
BLOWER MOTOR INSULATION

(W/DIESEL) REPLACEMENT
The 6.2 Liter Diesel Engine has extra insulation around
the blower motor on vehicles w ithout air conditioning and
around the blower motor and evaporator core with air
conditioning option (figure 55).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1. Parking lamp assembly.
Insulation through the hood opening.

4. Blower motor (482).
1. Blower motor (482).

2. Insulation (481).
3. Radiator overflow tank.
4. Parking lamp assembly.
A/C evaporator core procedure.

Insulation (481).
Insulation m ounting screws.
Lower section.
Heater valve assembly bracket.
Radiator.
Fan shroud upper half.
Blower motor relay and resistor.
W iring harness.
High pressure line inlet and bracket.
Accumulator.
Low pressure vapor line.
Refrigerant to the system.
W indshield solvent tank.
Hood latch assem bly and cable retainer.
Cold air intake.
EVAPORATOR CORE
REPLACEMENT
Remove or Disconnect (Figure2 54 and 55)

2. Radiator overflow tank.
3. Blower motor insulation (481).
W hen rem oving A/C com ponents, cap the

lines and openings to prevent contamination.
Low pressure vapor line and move it out of the way.
Accumulator.
High pressure line inlet to the evaporator and the
connecting bracket.
W iring harness going to the blower motor relay and
resistor.
Blower motor relay and resistor.
Fan shroud upper half.
Radiator.
Heater valve assembly bracket and move it out of
the way.
Upper screws of the lower section.
Push it down and out of the way.
Insulation mounting screws.
Insulation through the hood opening.
Proceed with the A/C evaporator procedure.
|<"+| Remove or Disconnect (Figure 54)

1.
2.
3.
4.
5.
6.
7.

Refrigerant from the system.
Coolant recovery tank and bracket.
Electrical connectors from the core case assembly.
Bracket at the evaporator case.
Right marker lamp for access.
Accum ulator inlet and outlet lines, and the two
brackets that attach the accum ulator to the case.
8. Evaporator inlet line.
Figure 55Blower Motor Insulation 6.2L Engine

9. Three (3) nuts and one (1) screw attaching module
to the dash panel.
10. Core case assembly from the vehicle.
11. Screws and separate the case sections.
12. Evaporator core.
1. New core.
A dd 90 ml (3 o u n c e s ) or 525 v is c o s ity
refrigeration oil to a new condenser.
2. Screws and the case sections.
3. Core case assem bly to the vehicle.
4. Module to the dash panel.
5. Evaporator inlet line.
6. Accum ulator inlet and outlet lines.
7. Two brackets that hold the accum ulator to the case.
8. Right marker lamp.
9. Bracket to the evaporator case.
10. Electrical connectors.
11. Coolant recovery tank and bracket.
BLOWER MOTOR
REPLACEMENT
Remove or D isconnect (Figure 54)
2. Coolant recovery tank.
3. Power antenna.
4. Blower motor lead wire.

5. Motor and wheel assembly (433).
Five blower motor m ounting screws.
Pry gently on the blower flange if the sealer
acts as an adhesive.
6. Blower wheel to motor shaft nut.
7. Separate the wheel and motor assemblies.

1. Wheel to the blower motor.
Assemble the blower wheel to the motor with
the open end of the wheel away from the
blower motor.
2. Blower wheel to the m otor shaft nut.
3. Blower wheel and motor assem bly to the vehicle.
If the m otor m o u n tin g fla n g e se a le r has
hardened or is not intact, remove the old
sealer and apply a bead of sealer to the
mounting flange.
Check blower operations: blower wheel should
rotate with no interference.
4. Blower motor lead wire.
5. Coolant recovery tank and power antenna.

Lower right tab.
5. Electrical harness (502) (figure 58).
6. Vacuum harness (506) (figure 59).
7. Control assembly.
Install or Connect (Figures 56, 57, 58 and 59)

1. Electrical and vacuum connection to the control.
2. Control into the opening in the dash panel.
3. Temperature cable.
^ 4 9 0 . In s tru m e n t Panel
491. C o n tro l
_ 492. S cre w ^
492
F-00332
CONTROL ASSEMBLY
REPLACEMENT
T e m p e ra tu re d o o r o p e ra tio n . R e feto
r
Temperature Door Cable A djustm ent.
Remove or Disconnect (Figures 56, 57, 58 and

59)
Headlamp switch control knob.
Control (491) (figure 56).
Screws.
Temperature cable eyelet clip and retainer
(499) (figure 57).
Control lower right mounting tab through dash
opening.
Upper tab.
491.
495.
496.
497.

5. Headlmap switch control knob.
Figure 56Control Assembly Removal
1.
2.
3.
4.
Adjust
TEMPERATURE DOOR
CABLE ADJUSTMENT
Adjust (Figure 56)
1. Remove instrum ent panel compartm ent and door.
2. Loosen the cable attaching screw at the selector

duct assembly.
Make sure the cable is installed in the bracket
on the selector duct assembly.
3. Place the temperature lever in full HOT position and
hold while tightening the cable attaching screw.
Install instrum ent panel com partm ent and door.
C o n tro l A s s e m b ly
D e fro s te r D u ct
T e m p eratu re C able
H e a te r A n d D e fro s te r
A s s e m b ly
498. B ra cke t
499. R e ta in e r
view
[1]
F-00324
Figure 57Temperature Control Cable

495
O ra n g e D o u b le B la c k
S trip e W ire
491. C o n tro l A s s e m b ly
495. D e fro s te r D u c t
B o d y W irin g H arne ss
A/C W irin g H a rn e s s
B lo w e r M o to r S w itc h
In s tru m e n t Panel H a rn e s s
Ig n itio n
F-00348
Figure 58Instrument Panel Wiring Harness
I.
E.
H.
K.
F.
491.
495.
497.
502.
506.
V a cuu m L in e Tan
V a cu u m L in e G ray
V a cu u m L in e D ark B lue
V a cu u m L in e Red
V a cuu m L in e O ran ge
C o n tro l
D e fro s te r D u c t
H e a te r A n d D e fro s te r A s s e m b ly
A/C H a rn e s s
A/C V a cuu m H a rn e s s
F-00326
Figure 59Vacuum Harness Assembly
491. C o n tro l
A s s e m b ly
1. Relay (511).
Screws.
493. B lo w e r M o to r
S w itc h
A/C DUCT WORK

REPLACEMENT
L i 493
F-00355
Figure 60Blower Switch Wiring Harness
BLOWER SWITCH
REPLACEMENT

60)

2. Left-foot cooler outlet assembly at the instrument
panel attachment.
3. Electrical harness (figure 60).
4. M ounting screws.
5. Control assembly (491).
6. Switch (493).
2. Engine cover.
3. Steering column to the instrument panel attaching
screws.
4. Radio,support bracket screw.
Pull the right side of the instrument panel
rearward.
7. Duct (distributor) attaching screws.
8. Center deflector (527) (figure 62).
-4- Install or Connect (Figure 62)
1. Center deflector (527).
3. Radio support bracket.
4. Steering column.
5. Engine cover.
DEFROSTER DUCT
REPLACEMENT

1. New switch.
Mounting screws.
To remove the defroster duct mounting, refer to figure

62.
3. Control assembly (491).
4. Left-foot cooler outlet assembly.
2. Resistor mounting screws.
3. Resistor (510) (figure 61).

1. Resistor (510).
Screws.
BLOWER MOTOR RELAY

REPLACEMENT
2. Relay mounting screw.
3. Relay (511).
TEMPERATURE DOOR
CABLE REPLACEMENT
To remove the temperature door cable refer to Control
Assembly R eplacem ent and figure 57.
VACUUM TANK REPLACMENT

1.
2.
3.
4.
Raise the hood.

Vacuum harness at the tank (552).
Tank attaching screws.
Tank (551).

1. Tank (551).
2. Vacuum harness.
3. Lower the hood.
VACUUM LINES
ENGINE COMPARTMENT
For vacuum line assemblies, refer to figures:
1. 4.3L Engine (figure 63).
2. 5.0L and 5.7L Engine (figure 64).
433
418.
433.
435.
497.
497
435
C o m p re s s o r
M o to r
A c c u m u la to r/D e h y d ra to r A s s e m b ly
E v a p o ra to r B lo w e r M o to r A s s e m b ly
502.
510.
511.
512.
513.
A/C H a rn e s s
R e s is to r A s s e m b ly
R elay A s s e m b ly
J u n c tio n B lo c k
T h ro ttle S o le n o id
F-00327
Figure 61Wiring Engine Compartment
REFRIGERANT-12
HOSE ROUTING
For Refrigerant-12 hose assemblies refer to:
2. 5.0L and 5.7L Engine (figure 67).
525
529 528 530

525.
526.
527.
528.
529.
D u ct A s s e m b ly
S crew
W a sh er
D e fle c to r A s s e m b ly
530. Bezel
531.
532.
533.
534.
535.
536.
S crew
Seal
G a ske t
G a ske t
D uct
531 536
537.
538.
539.
540.
541.
542.
531
H e a te r A s s e m b ly
S u p p o rt
S cre w
N ut
In le t A s s e m b ly
543.
544.
545.
546.
547.
548.
Seal
D uct
N ut
D uct
D uct
D uct
F-00279
Figure 62Duct Component View
553. V acuum F ittin g

554. Cap
C60
F-00328
Figure 63Vacuum Tank Assembly 4.3L Engine
Figure 64Vacuum Tank Assembly 5.0 and 5.7L Engine
552. V a cu u m Line
555. V a cu u m P um p
F-00330
Figure 65Vacuum Tank Assembly 6.2L Engine
97. R e frig e ra n t H ose
107. E v a p o ra to r and
B lo w e r A s s e m b ly
276. R a d ia to r
F-00386
Figure 664.3L Engine Refrigerant Hose Assembly
Figure 675.0L and 5.7L Engines Refrigerant Hose

Assembly
70.
97.
107.
275.
276.
C ondenser
R e frig e ra n t H o se
E va po rato r A n d B lo w e r A s s e m b ly
C o m p re s s o r
R a d ia to r
F-00387
Figure 686.2L Engine Refrigerant Hose Assembly
REAR INTERIOR ROOF MOUNTED SYSTEMG SERIES

This system is used in conjunction with the front mounted air conditioning system, and is almost identical to the R/V
rear interior roof mounted system. For servicing, refer to figure 69.
Figure 69G-Rear Interior Roof Mounted System Component View
1.
2.
3.
4.
5.
7.
8.
9.
10.
Seal
H ose
S crew
C la m p
G ro m m e t
E va po rato r
B ra cke t
B ra cke t
H ose
11.
12.
13.
14.
15.
16.
17.
18.
19.
S h ie ld
P late
P late
Tube
C lip
Tube
G ro m m e t
S cre w
C ondenser
20.
21.
22.
23.
26.
27.
28.
29.
30.
Tube
C ap
F ittin g
W a sh e r
Tube
S cre w
A c c u m u la to r
B ra cke t
R e ta in e r
31.
32.
33.
34.
35.
36.
37.
38.
Tube
S w itc h
S cre w
R e s is to r
C ase
S w itc h
N ut
S cre w
39.
40.
41.
42.
43.
44.
45.
46.
W a sh e r
S w itc h
S h ro u d
D e fle c to r
S lip
S crew
S cre w
S u p p o rt
F-03320
R-Rear Interior Roof Mounted System Component View
A/C SYSTEM P SERIES
Figure 71P-Compressor Installation

The compresser and condenser are installed on the ve
hicle during assembly. They are removed and shipped
separately.
For reference refer to the following figures:

1. Condenser M ounting - refer to figure 70.
2. Compressor Installation - refer to figure 71.
SPECIFICATIONS
A-6 COMPRESSOR
T ype.................................................................................................................................................................................. 6 Cylinder Axial
D isplace m en t..........................................................................................................................................................................12.6 Cu. In.
R otation.......................................................................................................................................................................................Clockwise
SYSTEM CAPACITIES
R e frig e ra n t.................................................................................................................................... 1.587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O il.............................................................................................................. 0.284 Kg. (10 ounces)
TORQUE SPECIFICATIONS
Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. Ib.s)
Oil Drain S c re w ......................................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure S w itc h .................................................................................................................................... 10 N m (7.5 ft. lbs.)
Engine Bracket M ounting B o lts ......................................................................................................................... 28 N m (21 ft. lbs.)
Compressor Support Bracket B o lts .............................................................................................................. .. .27 N m (20 ft. lbs.)
All Other Mounting B o lts .................................................................................................................................... 43 N m (32 ft. lbs.)
DA-6 COMPRESSOR
T ype ................................... ...............................................................................................................................................6 Cylinder Axial
D is p la ce m e n t..........................................................................................................................................................................10.0 Cu. In.
SYSTEM CAPACITIES
R e frig e ra n t.........................................................................................................................................1.587 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O il................................................................................................................ 0.227 Kg. (8 ounces)
Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. lbs.)
Shaft N u t................................................................................................................................................................. 16 N m (12 ft. lbs.)
Cycling Pressure S w itc h .................................................................................................................................... 10 N m (7.5 ft. lbs.)
Front Mounting Bracket Bolts (R /V )...................................................................................................................51 N m (38 ft. lbs.)
Front Mount Bracket Nut (R/V)........................................................................................................................... 24 N m (18 ft. lbs.)
Rear Brace Bolts (R /V ).........................................................................................................................................33 N m (20 ft. lbs.)
Rear Compressor Support Bolt (R/V-6.2L E n g in e ) ...................................................................................... 30 N m (22 ft. lbs.)
R-4 COMPRESSOR
Type................................................................................................................................................................................ 4 Cylinder Radial
D isp la ce m e n t..........................................................................................................................................................................10.0 Cu. In.
SYSTEM CAPACITIES
R e frig e ra n t.................................................................................................................................... 1.587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O i l .............................................................................................................. 0.312 Kg. (11 ounces)
Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. lbs.)
Oil Drain S c re w ......................................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure Switch .....................................................................................................................................10 N m (7.5 ft. lbs.)
Front and Rear Compressor Support Belts..................................................................................................... 50 N m (37 ft. lbs.)
Support Bracket B olt............................................................................................................................................. 83 N m (61 ft. lbs.)
Rear Support Brace Nut and B o lts .................................................................................................................. 33 N m (24 ft. lbs.)
SPECIFICATIONS (CONT.)
Blower Motor
R/V All Weather
R/V-G Rear Interior Roof Mounted
G Floor
Volts
Amps
(Cold)
RPM
(Cold)
12.0
12.8 Maximum
3400 Minimum
12.0
13.7 Maximum
3400 Minimum
Compressor Clutch Coil

Ohms (at 80 F ) ...................................................................................................................................................................................3.70
Am ps (at 8 0 F )...............................................................................................................................................................3.33 @ 12 Volts
Belt T ension...............................................................................................................................................................See Tune-Up Chart
Fuse Block
R/V S e rie s................................................................................................................................................................................ 25 Amps
In Line
R/V S e rie s................................................................................................................................................................................ 25 Amps
C ircuit Breaker
G Series . . .
45 Am ps
SPECIAL TOOLS
J-5420
J-6274-01
J-23575-01
J-6272-02
J-23600-B
J-9459
J-29547
J-23500-01
1.
2.
3.
4.
5.
6.
7.
8.
S tra ig h t A d a p te r
R e frig e ra n t Can Taps-AII Valve
M u lti-C a n D is p e n s in g Valve
90 D egree A d a p te r
P o rta b le C h a rg in g S ta tio n
C o m p le te M a n ifo ld A s s e m b ly
B e lt T ension G auge
A u to b a la n c e R e frig e ra n t Leak D e te c to r
F-02406
2A-1
SECTION 2
FRAME AND SH EET METAL

CONTENTS
SUBJECT
PAGE
Frame and B um pers...................................................................................................................................................... 2A-1

Sheet M e ta l.....................................................................................................................................................................2B-1
SECTION 2A
FRAME AND BUM PERS

CONTENTS
SUBJECT
PAGE
R/V And P Model Fram es............................................................................................................................................ 2A- 2

Description.................................................................................................................................................................2A- 2
Diagnosis Of The Frame.............................................................................................................................................. 2A- 2
Minimizing Frame Service........................................................................................................................................ 2A- 4
Checking Frame Alignm ent...................................................................................................................................... 2A- 4
Straightening F ra m e s.............................................................................................................................................. 2A- 5
Repairing C racks.......................................................................................................................................................2A- 5
W elding.......................................................................................................................................................................2A- 6
G Model U n d erb o dy.....................................................................................................................................................2A- 6
Description.................................................................................................................................................................2A- 6
Underbody A lig nm en t.............................................................................................................................................. 2A- 6
R/V Model Bumpers...................................................................................................................................................... 2A- 7
Front Bumper Replacem ent....................... ......................................................................................................... 2A- 7
Rear Bumper Replacement (Utility Vehicle and Suburban)................................................................................ 2A- 8
Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew C a b )............................................................2A-11
Rear Step Bumper R eplacem ent............................................................................ ........................................... 2A-12
Rear Bumper License Plate Bracket Replacement...............................................................................................2A-13
Dead Weight Trailer Hitch Replacement (Utility Vehicle and Suburban)..........................................................2A - 13
Weight Distribution Hitch Replacement (Suburban O n ly ).................................................................................. 2A-14
Weight Distribution Hitch Replacement (Utility Vehicle Only)............................................................................ 2A - 15
P Model B um pe rs........................................................................................................................................................ 2A-15
Front Bumper Replacement....................................................................................................................................2A-15
Front Bumper Replacement (With RPO FS3 Front A xle ).....................................................................................2A-16
G Model B um pers........................................................................................................................................................ 2A - 18
Front Bumper Replacement....................................................................................................................................2A-18
Rear Bumper Replacement......................................................................................................................................2A-19
Rear License Plate Bracket Replacement............................................................................................................. 2A-19
Dead Weight Trailer Hitch Replacement............................................................................................................... 2A-20
Weight Distribution Hitch Replacement................................................................................................................. 2A-20
S pecifica tio ns.............................................................................................................................................................. 2A-22
2A-2 FRAME AND BUMPERS
R/V AND P MODEL FRAMES

DESCRIPTION
The models covered under this part of the section
include R/V, and P. The service information for the G
model will be found in the underbody portion of this
section.
Proper frame alignm ent is important to assure normal
life and functioning of many other parts of the vehicle. If
the vehicle has been involved in a fire, collision, or has
been overloaded, there is cause to check the frame
a lig n m e n t. If, fo r any o th e r re a so n , a lig n m e n t is
suspected it should be checked. A procedure for this is
described later in this section under Checking Frame
Alignm ent.
It is possible that certain conditions make the frame
appear to be out of alignm ent when, in fact, it is not.
These conditions are also described under Checking
Frame Alignm ent.
Terms used later in this section are briefly defined
below:
1. SECTION MODULUSThis is a measure of the
strength of a frame, based on height, width, thickness
and shape of the side rails. It does not account for the
strength of the material used in the frame.
2. YIELD STRENGTHThis is a measure of the strength

of the material from which the frame is made. It is the
maximum load measured in kPa (psi) that can be
placed on a material and still have it return to its
original shape.
3. RESISTANCE TO BENDING MOMENT (RBM)This is
a single measure of frame strength that accounts for
both the section modulus and the strength of the
material used. It is the product of section modulus and
yield strength.
4. SAGThis refers to a frame or side rail that is bent
down from where it should be.
5. BUCKLEThis refers to a frame or side rail that is
bent up from where it should be.
6. DIAMONDThis refers to the condition where one
entire frame rail is moved forward from, or to the rear
of, its correct alignment with the other rail.
7. TWISTThis refers to the condition where the entire
frame has been twisted. One rail will basically slope up
while the other rail will basically slope down.
8. SIDESWAYThis refers to a side rail that is bent to the
side of where it should be.
9. TRACKINGThis refers to the alignment of the vehicle
axles with each other. A misaligned frame can cause
improper tracking. If the vehicle is tracking correctly, all
axles will be parallel to each other and perpendicular
to the center line of frame.
10. WEBThe vertical part of a channel-type frame rail.
DIAGNOSIS OF THE FRAME

PROBLEM
Sag
POSSIBLE CAUSE
CORRECTION
1. Loads greater than the fram e is de

signed to carry.
2. Uneven load distribution.
3. Abrupt changes in section modulus. (For
a brief definition of section modulus, see
the Description at the beginning of this
section.
4. Improper body, or accessory, mounting:
Holes drilled in the flange of the frame
rail.
Too many holes in the web section of the
rail.
Holes in the web section which are too
close to each other.
Four or more holes in the same vertical
line of the rail web.
Welds on the flange, particularly across
the flange or along its edge.
Cutting holes in the rail with a torch.
Cutting notches anywhere on the rails.
5. A fire involving the vehicle.
6. A collision involving the vehicle.
7. The use of equipm ent for which the
frame has not been designed or rein
forced.
1-7. Straighten and reinforce the frame as

described later in this section. See
S traightening Fram es and R ein
forcem ents.
FRAME AND BUMPERS 2A-3
DIAGNOSIS OF THE FRAME (CONT.)

POSSIBLE CAUSE
CORRECTION
Buckle
1. The use of equipm ent such as snow

plows for which the frame was not de
signed.
4. In addition to these causes, refer to pos
sible causes 3 and 4 under S a g .
These may contribute to Buckle.
1-4. Straighten and reinforce the fram e as

described later in this section. See
S tra igh ten ing Fram es and R ein
forcem ents.
Sidesway

3. The use of equipm ent such as snow
plows for which the frame was neither
designed nor properly reinforced.
4. In addition to these causes, refer to pos
sible causes 3 and 4 under S a g .
These may be contributing factors.

described later in this section. Refer to
forcem ents.
Diamond

2. Towing another vehicle with a chain at
tached to one corner of the frame.

forcem ents.
Twist
1. An accident or collision involving the ve

hicle.
2. Operating the vehicle in very rough ter
rain.

forcem ents.
Improper Tracking
1. Frame is out of alignment.
PROBLEM
2. Front or rear axle has shifted.

3. Incorrect wheel alignm ent may make the
vehicle appear to be tracking incorrectly.
Cracks In The Web Of

The Rails
1. Loose crossmember attaching bolts.
2. Concentration of stress that may result

from many different factors. Refer to
S a g under D iag no sis previously
described in this chart. Also refer to
M inim izing Frame Damage and Rein
forcem ents later in this section.
1. Straighten and reinforce the fram e as

described later in this section.
2. Realign and secure the axle.
3. Align the wheels. Refer to FRONT END
ALIGNM ENT (SEC. 3A) of this manual.
1. Replace, or weld and reinforce rail.
Ream b olt holes and rep la ce w ith
larger bolts if necessary. R etighten
bolts.
2. Replace, or weld and reinforce the rail.
See the appropriate heading, later in
this section.
Figure 1R/V and P Model Frames
MINIMIZING FRAME SERVICE
CHECKING FRAME ALIGNMENT
G e n e ra lly , fra m e s e rv ic e can be m in im iz e d or

eliminated by m inimizing the concentration of stress in
small areas of the frame.
1. Vehicles should be used only for those purposes for
which they were designed.
They should not be overloaded.
They should be loaded evenly; localized loads
should be avoided.
Do not operate the vehicle on extremely rough
terrain.
Take into account the forces that will be placed
on a frame from the operation of equipment such
as snow plows when picking a frame for a new
vehicle or reinforcing a frame.
2. Follow recommended practices when repairing a frame
or when mounting a body or equipment on a frame.
Avoid sudden changes in the section modulus.
Do not drill holes in the frame rail flanges.
Space holes in the web section of a rail at least
13 mm (1/2-inch) from one another.
Use existing holes whenever possible.
Do not cut holes with a torch.
Do not overheat the frame rails.
Avoid welding on the flanges.
Do not allow four or more holes to exist on the
same vertical line of the web.
Holes made in a reinforcement should be placed
a distance of at least two times the material
thickness from the edge of the reinforcement.
The main parts of a fram e are the side rails and

c ro s s m e m b e rs . T he ra ils c a rry th e load and th e
crossmembers stabilize the rails.
Types of fram e m isalignm ent can be divided into five
groups. The five groups are sag, buckle, diam ond,
sidesways, and twist. For a brief definition of these terms,
refer to Description at the beginning of this section.
A misaligned frame rail may have moved forward from,
up or down from, or to the side of where it should be.
These possibilities must be checked.
The easiest way to check fram e alignm ent is with gages
made for this purpose. Detailed instructions are normally
supplied with gages at the tim e of purchase. Therefore,
instructions for gage use are not given in this manual.
It is p ossible to ch eck c e rta in p o rtio n s of fram e
alignm ent w ithout the proper gages. The procedure is
described later in this section.
W hether alignm ent is checked with or w ithout gages,
the vehicle must be parked on a level section of floor.
Certain conditions call for prelim inary checks before
actually checking the frame. Suspension or axle problems
may make it appear that the vehicle frame is out of
a lig n m e n t. If an a xle has s h ifte d , D ia m o n d or
Sidesway may appear to exist when, in fact, they do
not. A weak spring may make the vehicle appear to have
a twisted frame.
A visual inspection of the top and bottom flanges of
each rail may reveal the specific area where sag or buckle
exists. In the case of sag, wrinkles may appear on the top

of the upper flange; such w rinkles are definite evidence of
sag. W rinkles on the bottom of the lower flange are
definite evidence of buckle.
DETERMINING THE FRAME CENTERLINE (Figure 1)

1. Move the vehicle to a level, well-lighted section of the
floor.
2. Make a diagram of the frame on the floor beneath the
vehicle as follows:
a. Using a plumb bob, transfer points 1, 2, 11, 12
from the inside of the web to the floor. Mark the
points (figure 1).
b. Using a plumb bob, transfer the remaining points
from the outside of the web to the floor. Mark the
points. Be sure to use points from the same
place on both the right and left frame rail.
3. Move the vehicle away from the points on the floor.
4. Measure the distance between points 1 and 2. This
distance should be 704.85 mm (27.75-inch) for the
standard front axle, and 847.25 mm (33.75-inch) if
equipped with a 5000# I-Beam Front Axle.
5. Measure the distance between points 11 and 12. This
distance should be 847.25 mm (33.75-inch). If both the
measurements in steps 4 and 5 were correct, continue
the procedure. If the measurements are not correct,
refer to Horizontal Check step 2, and mark the
centerline through the intersection of two sets of
diagonals that have equal measurements.
6. Make a mark on the floor exactly halfway between
points 1 and 2. Make a similar mark between points 11
and 12.
7. Use a chalk line to mark a line through the points. This
is the centerline of the frame.
HORIZONTAL CHECK
1. Measure the distance between the frame rails, and the
centerline at points 3-10. Each pair of corresponding
points should be an equal distance from the centerline
within 3 mm (Vs-inch). Example: Points 3 and 4 should
measure equally from the centerline as should points 5
and 6, 7 and 8, and points 9 and 10.
2. Measure diagonally from point 1 to point 6, and from
point 2 to point 5. Mark the floor where the diagonals
pass the centerline. The diagonals should measure the
same distance within 5 mm (3/ie-inch), and should
cross at the ce n te rlin e . If the fram e is w ithin
specifications, the frame within these points is properly
aligned.
3. Repeat step 2 on other pairs of diagonals until the
entire frame has been checked. Example: Point 3 to
point 10 and point 4 to point 9 or point 5 to point 12 and
point 6 to point 11, etc.
4. Refer to Straightening Frames to repair any damage
that is found.
STRAIGHTENING FRAMES
Frame straightening can be complicated and usually
requires special equipment. It should be attempted by
competent personnel only.
A com plete analysis of the condition of the fram e
should be made before any steps are taken to straighten
it. Analyzing the cause of failure will help determine the
c o rre ct sequence of steps in the repair. (R efer to
Figure 2Types of Frame Cracks

Possible C auses under Diagnosis and M inim izing
Frame S e rvice p reviously o utline d in th is section.)
Corrective procedures should be set up to reverse the
flow of the dam aging forces. In many instances, to reverse
the flow of forces, pressure must be applied from different
directions at the same time.
Careful use of controlled heat is important. Too much or
too little heat, or the im proper application of heat, is a
m ajor source of trouble. Frame heating should be done
with a large sized tip (multi-hole heating tip) and a neutral
flame should be used (oxygen adjust opened just enough
to remove the feathers or stringers from the blue center at
tip of torch). Heat the area that will be stretched as frame
is straightened. Heat the area AFTER SU FFIC IEN T
PRESSURE HAS BEEN EXERTED to cause a slight
checking, or silvery cracks, to appear on the surface of
the metal. Gradually increase the pressure while heating.
Do not heat beyond 606C (1200F). A red glow indicates
that the material is overheated. Overheating will cause
distortion and stretching, as well as a change in the
characteristics of the metal.
REPAIRING CRACKS
Two common types of cracks are shown in figure 2. The
straight crack will norm ally start from the edge of a flange.
It will go across the flange and through the web section of
a rail. Finally, it will continue through the other flange.
This type of crack may result from high concentrations of
stress in small areas of the frame, excessive bending
moment, and torsional loading. (Refer to M inim izing
Frame Service, previously outlined in this section).

Sunburst crack(s) will radiate out from a hole in the web
section of a rail or crossmember. They are caused by high
lo a d s b e in g a p p lie d a t a m o u n tin g b ra c k e t o r
crossmember which is not securely or properly attached
to the rail.
If cracks occur to both the rail and reinforcement at a
particular area of the frame, they must be repaired
separately. The flanges must react independently to
prevent localized stress concentration. Use a copper
spacer between the flanges of cracked base rail flanges
and reinforcement flanges.
Crossmember mounting flange cracks may be repaired
in the same m anner as side rail cracks. However, weld
bead should be built up to provide a good smooth radius.
If a crossm em ber is greatly damaged replace it.
It may be necessary to align the frame and level the
rails before repairing the frame.
1. Remove any equipment that will interfere with access
to the crack.
2. Locate the extreme end of the crack and drill a 6 mm
(0.25-inch) hole.
3. V grind the entire length of the crack from the
starting point to the 6 mm (0.25-inch) hole at the
extreme end.
4. Open up the bottom of the crack 2 mm (V-ie-inch) to
allow good penetration of the weld. (A hack-saw blade
may be used for this).
5. Weld with proper electrode and proper welding
techniques. Refer to Welding outlined later in this
section for tips on welding.
6. Grind the weld smooth on both the inside and the
outside of the rail or crossmember. Be extremely
careful to eliminate weld build-up or notches on the
edge of the flange.
WELDING
Improper welding techniques are the cause of many
weld and/or frame failures. The following information
points out potential areas of difficulty and provides some
general guidelines for successful frame welding.
Most weld failures occur at the end of the weld in areas

of the frame that are under high stress. By elim inating the
ends of a weld, failures can be reduced; this can be done
by making a hole or slot in the part to be attached and
then using a fillet weld around a slot or plug weld. Do not
leave a notch at the end of a weld.
Over-welding can be harmful, especially if it is in an
area of the frame that receives high concentrations of
stress.
Small cracks in a crossm em ber may be welded. (Refer
to Repairing Cracks previously outlined in this section).
When welding:
1. Do not use oxyacetylene welding equipment.
2. Whenever possible, use smaller diameter electrodes
and make several passes; this is preferred to using a
large diameter electrode and making fewer passes.
3. Do not use more heat than is necessary to give good
penetration.
4. Do not run more passes than necessary.
5. Make sure the weld is free from craters and undercuts.
6. Make sure scale is removed from each successive
pass.
7. If repairing a crack, grind the surface of the weld flush
with the parent material.
8. When mounting accessories, do not weld across the
flanges.
9. When mounting accessories, do not weld within 19 mm
(3/4-inch) of a flange.
10. Do not weld up to the edge of a part being welded to a
frame. Leave 6 mm (0.25-inch) between the end of the
weld and the edge of the part.
11. Do not weld cast brackets to the frame.
12. Do not weld the flanges of cracked reinforcements and
base rails together.
13. Connect the welding machine ground cables as close
to the working area as possible.
14. Avoid direct contact between the welding cables and
any part of the vehicle.
15. Do not get the welding cables near the vehicle wiring.
G MODEL UNDERBODY
DESCRIPTION
The G Model incorporates a unitized body design
comprised of side rails, cross sills, and outriggers which
are all part of the welded underbody.
A misaligned underbody can affect the operation of
many vehicle components. It is essential that underbody
alignm ent be exact to within 1.6 mm (1/ie-inch).
UNDERBODY ALIGNMENT
To determine the alignm ent of the underbody it is
necessary to use a good quality tram ing gage. This gage
must be capable of m easuring all points of the underbody
up to three quarters of the body length.
Following the instructions given by the m anufacturer of
your gage, measure the horizontal and vertical points as
shown in figure 3. Compare each measurement with the
s p e c ific a tio n s given in the fig u re to d ete rm ine the

damaged areas and the extend of the damage. When
repairing the underbody it will be necessary to return the
underbody to these original specifications within 1.6 mm
(1/ie-inch).
Many different types and brands of unibody repair
equipm ent are available; each system may be slightly
different. A multiple pull system is most desirable in order
to correct the damage in the same direction in which it
was created. When m aking m ultiple pulls use the last in,
first out procedure. This means that you correct the
damage in the reverse sequence by which it was created.
It is also important to correct the damage in the opposite
direction in which the damage was created.
15.
16.
A.
B.
C.
D.
E.
F.
F ro n t Gage H o le s
Rear Gage H ole s
789.4 m m (31.08-inch)
1041.4 m m (41.0-inch)
1340 m m (52.76-inch)
1041.4 m m (41.0-inch)
126 m m (4.96-inch)
123 m m (4.8-inch)
113.3 m m (4.46-inch)
13 m m (0.51-inch)
96 m m (3.78-inch)
J. 145.2 m m (5.72-inch)
K. 701 m m (27.6-inch)
1465
1845
M. 2772
3153
N. 2806
3415
mm
mm
mm
mm
mm
mm
(57.66-inch) 110-inch w h e e lb a s e
F-02180
Figure 3G Model Underbody
R/V MODEL BUMPERS

FRONT BUMPER
REPLACEMENT
Remove or Disconnect
1. Brace to bumper nuts (52) (figure 1).
2. Bracket to bumper nuts (53).
3. Bumper from the vehicle.
4. Guard assemblies (where used) (figure 5).
5. Rub strips from the bumper and guards (where used)
(figure 6).
From the rear of the bumper, press the tangs of
the rub strip together, and push the strip from the
bumper and/or guard.
Install or Connect (Figures 4-8)

1. Brackets and tow hooks (where used) to the frame rails.
On vehicles without tow hooks, install the bolts
and washers through the brackets and through
the outside of the frame rail.
On vehicles with tow hooks, install the tow hook
bolts and washers from inside the frame rail,
then through the brackets and the tow hooks.
Install the top bracket bolts and washers through
the bracket, and into the top rail flange.
2. Washers and nuts to the bolts.
Tighten
Nuts to 95 N m (70 ft. lbs.).
Brace bolts and washers (67 and 68) through the frame
rails and into the braces.
6. Bumper bolts (56 and/or 58).

7. Brace bolts and washers (67 and 68) (figure 7) from the
inside of the frame rail.
Braces (54).
8. Bracket bolts, washers, and nuts (66, 65 and 64) from
the frame.
9. Tow hooks (70) (where used).
10. Brackets (55).

4. Bumper bolts (56) onto the bumper.
5. Rub strips to the bumper and guards (where used).
Place the tangs of the strips onto the slots in the
bumper or guard. Using a rubber mallet, set the
tangs in place starting at the center of the strip,
and working toward each end.
6. Guard assemblies (where used).
7. Bumper to the vehicle.
Figure 4R/V Front Bumper Components

Install the bumper with bolts through the right
and left braces, and brackets.
8. Bracket to bumper nuts (53).
Tighten
REAR BUMPER REPLACEMENT

(UTILITY VEHICLE AND
SUBURBAN)

9. Brace to bumper nuts (52).
Tighten
Figure 5R/V Front Bumper Guards
1.
2.
3.
4.
5.
6.
Brace to bumper nuts (71).

Bracket to bumper nuts (74).
Rear bumper.
Filler panel bolts (figures 9 and 10).
Filler panel.
Rub strips from the bumper (where used) (figure 24).
From the rear of the bumper, press the tangs of
the bump strip together, and push the strip from
the bumper.
7. Bumper bolts (82).
8. Brace nuts, washers, and bolts (76, 75 and 80).
Braces (72).
9. Bracket nuts, washers, and bolts (77, 78 and 79).
Brackets (72).
Figure 6R/V Front Bumper Rub Strip
54
54.
55.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
A.
B.
Brace
B ra cke t
B o lt
W a sh er
N ut
N ut
W a sh er
B o lt
B o lt
W a sh er
W a sh er
Tow H o o k
Fram e
W eld N ut
66
Figure 7R/V Front Bumper Brackets, Braces, and Tow Hooks
F-02176
51.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
82.
B u m p e r Bar
N ut
Brace
B ra cket
N ut
W a sh er
N ut
N ut
W a sh er
B o lt
B o lt
B o lt
F-02175
Figure 8Utility Vehicle and Suburban Rear Bumper Components

|+ + | Install or Connect (Figures 8-11)
1. Brackets to the frame rails (72).
Tighten
Bracket bolts, washers, and nuts (79, 78 and 77).
3. Bumper bolts to the bumper (82).

4. Rub strips to the bumper (where used).
Tighten

bumper guard. Using a rubber mallet, set the
tangs in place starting at the center of the strip,
working toward each end.

2. Braces to the frame rails (72).
Brace bolts, washers, and nuts (80, 75 and 76).
5. Filler panel supports (Utility vehicle only) (figure 9).
51.
83.
84.
85.
86.
87.
88.
B u m p e r Bar
Bar
U N ut
N u t and W a sh e r
S u p p o rt
B o lt
F ille r Panel
F-02174
Figure 9Rear Bumper Filler Strip

Tighten
Bolts to 10 N-m (89 in. lbs.).
10. Bracket nuts (74).
Nuts to 41 N-m (30 ft. lbs.).

11. Brace nuts (71).
Tighten

(REGULAR CAB, BONUS CAB,
AND CREW CAB)
Place the filler panel bolts through the panel and

into the support U nuts.
Tighten
Bolts to 10 N m (89 in. lbs.).
6. Filler panel (Suburban only) (figure 10).
Bolts through the filler panel, and into the
platform.
Bolts to 2.8 N-m (25 in. lbs.).

Install the bumper bolts (82) into the braces, and
brackets.
8. Filler panel (Utility vehicles only).
Place the filler panel behind the bumper, and
place the supports onto the bumper bolts behind
the braces.
9. Filler panel bracket bolts (Utility vehicle only).
1. Brace nuts (93), spring washers (94), and washers (95)

at the bumper.
2. Bracket nuts (99), spring washers (98), and washers at
the bumper.
3. Rear bumper from the vehicle.
4. Bumper bolts (106).
5. Gravel deflector nuts (107) and bolts (81) (where used)
(figure 13).
6. Gravel deflectors (105).
7. Brace to frame nuts (100), spring washers (102), and
bolts (104).
8. Braces (92).
9. Bracket to frame rail nuts (101), spring washers (102)
and bolts (103).
10. Brackets (96).
Install or Connect
1. Brackets to the frame rails.
2. Bolts (103), spring washers (102), and nuts (101).
Tighten
3. Braces to the frame rails.
4. Bolts (104), spring washers (102), and nuts (100).
Tighten

5. Gravel deflectors (where used).
6. Nuts (107) and bolts (81).
Tighten
Nuts to 10 N-m (89 in. lbs.).
7. Bumper bolts (106) onto the bumper.
8. Rear bumper.
Place the bumper bolts through the brackets and
braces.
9. Bracket washers (97), spring washers (98), and nuts
99) to the bumper.
Tighten
10. Brace washers (95), spring washers (94), and nuts (93)
to the bumper.
51.
92.
93.
96.
99.
100.
101.
102.
103.
104.
106.
B u m p e r Bar
Brace
N ut
B ra cke t
N ut
N ut
N ut
S p rin g W a sh er
B o lt
B o lt
B o lt
F-02313
Figure 12Regular Cab, Bonus Cab, and Crew Cab Rear Bumper Components
Tighten
REAR STEP BUMPER

REPLACEMENT
Nuts to 90 N m (66 ft. lbs,).

1. Bracket to bumper nuts (111), and bolts (112).
2. Brace to bumper nuts (119), spring washers (118),
washers (117), and bumper bolts.
4. Brace to frame nuts (108) and bolts (110).
5. Braces (54).
6. Bracket reinforcement nuts (115) and bolts (109) (and
washers (114) where used).
7. Bracket reinforcements (113).
8. Bracket to frame nuts (108), and bolts (110).
9. Brackets (55).
+ 4-
Brackets (55) and braces (54) to the frame.

Bolts (110) and nuts (108) loosely.
Bracket reinforcements (113).
The reinforcements are marked as right or left on
their inboard sides.
4. Bolts (109) and nuts (115), and washers (114) (where
used).
Tighten
Reinforcement nuts to 70 N-m (52 ft. lbs.).
Bracket and brace nuts to 70 N-m (52 ft. lbs.).
Bumper to the vehicle.
B u m p e r Bar
51.
54.
55.
108.
109.
110.
111.
112.
113.
114.
115.
116.
119.
Brace
B ra cket
N ut
B o lt
B o lt
B o lt
B o lt
R e in fo rc e m e n t
W a sh er
N ut
B o lt
N ut
119
F-02311
Figure 14Rear Step Bumper Components

6. Bumper to brace bolts (116), washers (117), spring
washers (118), and nuts (119).
5. Chain bracket.
6. Support.
Tighten
7. Bar assembly bolt and washer from the bracket.
7. Bumper to bracket bolts (112) and nuts (111).
Tighten
REAR BUMPER LICENSE

PLATE BRACKET
REPLACEMENT
8. Bar assembly.
+- Install or Connect (Figures 16 and 17)
1. Bracket assembly to the frame with bolts, washers, and
nuts.
1 11 Remove or Disconnect (Figure 15)

1. License plate bracket to bumper nuts (123), spring
washers (122), washers (121), and bolts (124).
2. License plate bracket (120).

1. License plate bracket (120).
2. License plate bracket to the bumper bolts (124),
washers (121), spring washers (122), and nuts (123).
Tighten
DEAD WEIGHT TRAILER

HITCH REPLACEMENT
(UTILITY VEHICLE AND
SUBURBAN)
1. Bracket assembly nuts, washers, and bolts from the
frame.
2. Support nuts, washers, and bolts from the bumper.
3. Hitch assembly.
4. Chain bracket nut, washer, and bolt.
51.
120.
121.
122.
123.
124.
B u m p e r Bar
L ic e n s e Plate B ra cke t
W a sh er
S p rin g W a sh er
N ut
B o lt
F-02310
Figure 15Rear License Plate Bracket
125
51. B u m p e r Bar
142
m
I32. C ha in B ra c k e t
144
134. Bar A s s e m b ly
145
136. B ra cket A s s e m b ly 14g
139.
B o lt
147.
140. W a sh e r
148
141.
86. S u p p o rt
51.
86.
125.
126.
127.
128.
129.
130.
131.
132.
133.
B u m p e r Bar
S u p p o rt
B o lt
W a sh er
N ut
W a sh er
B o lt
N ut
W a sh er
C hain B ra cket
B o lt
Nut
134.
135.
136.
137.
138.
B ar A s s e m b ly
B o lt
B ra cke t A s s e m b ly
W a sh er
N ut
149'
W a sh e r
B o lt
N ut
W asher
B o lt
B o lt
W asher
N ut
F-02308
Figure 17Utility Vehicle Dead Weight

Trailer Hitch
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
(SUBURBAN ONLY)
F-02309

Figure 16Suburban Dead Weight Trailer
Hitch Components
1. Rear bolts, washers, and nuts from the hitch.

2. Front nuts, washers, and bolts from the hitch.
Tighten
3. Hitch platform from the vehicle.
2. Bar assembly to the support.
Place the bolt through the bar assembly, support
and the chain bracket. Install the washer and nut
loosely.
3. Support assembly bolts through the support and the
bumper.
4. Washers and nuts loosely.
5. Bar assembly bolt with washer through the bar and
into the bracket assembly.

1. Hitch platform to the vehicle.
There must be no contact between the platform
and the rear bumper.
2. Front bolts, washers, and nuts to the hitch.
Assemble loosely.
3. Rear nuts, washers, and bolts to the hitch.
Install the nuts with the cut-off side outboard.
Tighten
Bar to bracket bolt to 95 N m (70 ft. lbs.).
Tighten
Bar to support nut to 70 N m (52 ft. lbs.).
Rear bolts to 95 N m (70 ft. lbs.).
Support to bumper nuts to 33 N m (24 ft. lbs.).
Front nuts to 70 N m (52 ft. lbs.).
51.
150.
151.
152.
153.
154.
155.
B u m p e r Bar
N ut
W a sh e r
B o lt
W a sh er
S p rin g W asher
B o lt
156. N ut
157. W a sh e r
158. P la tfo rm
51.
158.
159.
160.
161.
162.
163.
Figure 19Utility Vehicle Weight Distribution

Hitch Components
Figure 18Suburban Weight Distribution Hitch

Components
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
(UTILITY VEHICLE ONLY)
1. Rear bolts, washers, and nuts from the hitch.

2. Front bolts, washers, and nuts from the hitch.
3. Hitch platform from the vehicle.
B u m p e r Bar
P la tfo rm
164. S p rin g W a sh er
N ut
W a sh e r
165. B o lt ~
B o lt
166.
N ut
W a sh e r
167. W a sh er
W a sh e r
++

Hitch platform to the vehicle.
Front bolts, washers, and nuts to the hitch.
Assemble loosely.
Rear bolts, washers, and nuts to the hitch.
Install nuts with the cut off side inboard.
Rear bolts to 73 N m (54 ft. lbs.).

Front bolts to 70 N m (51 ft. lbs.).
P MODEL BUMPERS
FRONT BUMPER
REPLACEMENT
1. Brace to frame nuts (203), spring washers (202),
washers (201), and bolts (199).
2. Bracket to frame nuts (206), spring washers (205),
3. Bumper to frame nuts (187), spring washers (186),
washers (185), spacers (198) (where used), and bolts
(197).
Braces (54).
Bracket to bumper nuts (191), spring washers (190),

Braces to the bumper with bolts (197), washers (194),
spring washers (193), and nuts (192).
Assemble loosely.
2. Bracket to the bumper with bolts (197), washers (194),
Assemble loosely.
Bumper to vehicle.
Bumper to frame spacers (198) (where used), spring
washers (186), washers (185), bolts (197), and nuts
(187).
191
190 v
51.
54.
55.
185.
186.
187.
189.
190.
B u m p e r Bar
Brace
B ra cket
W a sh er
S p rin g W a sh e r
N ut
W a sh er
51
191.
192.
193.
194.
196.
N ut
N ut
S p rin g W a sh er
197. B o lt
W a sh er
198. S p a ce r
W a sh er
196
F-02305
Figure 20P-Front Bumper Components

Tighten
Tighten

5. Brackets to the frame rails with bolts (195), washers
204 spring washers (205), and nuts (206).
Brace to frame nuts to 85 N m (63 ft. lbs.).

Brace to bumper nuts to 47 N m (35 ft. lbs.).
FRONT BUMPER
REPLACEMENT (WITH
RPO FS3 FRONT AXLE)
Tighten
Bracket to frame nuts to 95 N m (70 ft. lbs.).

Bracket to bumper nuts to 47 N m (35 ft. lbs.).
6. Braces to the frame rails with bolts (199), washers
(201), spring washers (202), and nuts (203).
++
1. Bracket to frame nuts (207) and washers (208).

2. Brace to frame nuts (222), washers (221), and bolts
(219).
3. Front bumper from the vehicle.
4. Bracket to bumper nuts (218 and 223), spring washers
(217 and 224), washers (216 and 225), spacers (198),
and bolts (215).
5. Brackets (55).
7. Braces (54).
199
200

1. Braces to the bumper with bolts (215), washers (211),
Tighten
55.
72.
195.
199.
200.
B ra cket
Brace
B o lt
B o lt
W a sh er
201. W a sh er
202. S p rin g W a sh e r
203. N ut
2. Brackets to the bumper with bolts (213), spacers (198),

spring washers (217 and 224), washers (216 and 225),
and nuts (218 and 223).
204. W a sh er
205. S p rin g W a sh e r

3. Front bumper to the vehicle.
F-02304
Place the bracket assembly studs into the frame

crossmember.
Figure 21P-Front Bumper Braces and Brackets
4. Brace to frame bolts (219), washers (221), and nuts

( 222 ).
206. N ut
51.
54.
55.
207.
208.
209.
210.
211.
212.
213.
213
B u m p e r Bar
Brace
B ra cket
N ut
W a sh er
N ut
S p rin g W a sh er
W a sh er
W a sh er
B o lt
212
F-02303
Figure 22P-Front Bumper Components (RPO FS3 Front Axle)
Tighten

5. Bracket to frame washers (208) and nuts (207).
Tighten
51.
54.
55.
198.
214.
215.
216.
217.
218.
219.
220.
221.
222.
223.
224.
225.
B u m p e r Bar
B race
B ra cke t
S p a ce r
W a sh e r
B o lt
W a sh e r
S p rin g W a sh er
N ut
B o lt
W a sh e r
W a sh e r
N ut
N ut
S p rin g W a sh er
W a sh e r
198
225
F-02302
Figure 23P-Front Bumper Braces and Brackets (RPO FS3 Front Axle)
G MODEL BUMPERS
51.
54.
55.
239.
240.
241.
242.
243.
B u m p e r Bar
Brace
B ra cket
N ut
B o lt
N ut
B o lt
B o lt
F-02301
Figure 24G-Front Bumper Components
FRONT BUMPER
REPLACEMENT
4- +
1. Bracket to cross sill bolts (242).

2. Brace to bumper nuts (241) and bolts (243).
4. Bracket to bumper nuts (239), bolts (243), and guards
(where used).
5. Brackets (55).
6. Rub strips from the guards (where used) (figure 38).
From the rear of the guard, press the tangs of the
bump strip together, and push the strip from the
guard.
7. Brace to frame bolts (240).
Braces (54).
Bolts to 41 N-m (30 ft. lbs.).

7. Brace to bumper bolts (243) and nuts (241).

1. Braces to the frame.
Place braces through the holes in the cross sill,
and install the bolts (240) loosely.
2. Bolts (245) into the guards (where used).
3. Rub strips to the guards (where used).
guard. Using a rubber mallet, set the tangs in
place starting at the center of the strip, and
working toward each end.
4. Bracket to bumper bolts (243) or guards (where used),
nuts (239), and guard lower bolts.
Tighten
Guard lower bolts to 41 N m (30 ft. lbs.).
6. Bracket to cross sill bolts (242).
Brace to bumper nuts to 29 N-m (21 ft. lbs.).

Brace to frame bolts to 41 N-m (30 ft. lbs.).
51.
55.
246.
247.
248.
249.
250.
251.
252.
253.
254.
B u m p e r Bar
B ra cket
O u te r Brace
W a sh e r
B o lt
In n e r Brace
B o lt
N ut
B o lt
B o lt
B o lt
F-02299
Figure 26G-Rear Bumper Components
Tighten
&
++
1.
2.
3.
4.
5.
6.
7.
8.
9.
10

Outer brace to bumper nuts (251) and bolts (254).
Inner brace to cross sill bolts (253).
Bracket to frame bolts (248) and washers (247).
Bumper from the vehicle.
Outer brace to cross sill bolts (252).
Outer braces (246).
Bracket to bumper nuts and bolts (254).
Brackets (55).
Inner brace to bumper nuts (251) and bolts (254).
Inner braces (249).

Inner braces (249) to the bumper.
Assemble the top bolts (250) and nuts (251).
Tighten
Nut to 30 N m (22 ft. lbs.)
Assembly the lower bolts (254) and nuts (251).
Nut to 30 N-m (22 ft. lbs.).

2. Brackets to the frame with washers (247) and bolts
(248).
Assemble loosely.
3. Outer braces (246) to the cross sill with bolts (252).
Tighten
Place the inner braces into the inner brace panel
holes.
5. Inner braces to the cross sill with bolts (253).
Tighten
6. Bumper to bracket bolts (254) and nuts.
Bracket to frame bolts to 68 N m (50 ft. lbs.).

7. Outer bracket to bumper bolts (254) and nuts (251).
Tighten
REAR LICENSE PLATE

BRACKET REPLACEMENT
1. License plate bracket nuts and bolts.
2. License plate bracket.

1. License plate bracket.
2. License plate bracket nuts and bolts.
51.
55.
86.
132.
134.
136.
257.
258.
259.
260.
261.
262.
263.
264.
265.
266.
B u m p e r Bar
B ra cke t
S u p p o rt
C ha in B ra cke t
Bar A s s e m b ly
B ra cke t A s s e m b ly
W a sh er
N ut
B o lt
B o lt
N ut
B o lt
B o lt
N ut
N ut
S h im
F-02297
Figure 28Dead Weight Trailer Hitch
Tighten
DEAD WEIGHT TRAILER

HITCH REPLACEMENT
3. Support to the bumper with bolts and nuts.

Assemble loosely.
4. Bar assembly and chain bracket to the support with a
bolt and nut.
Tighten
Bar assembly to chain bracket nut to 68 N m (50
ft. lbs.).
Bar assembly to hitch bracket bolt to 68 N m (50
ft. lbs.).
Support to bumper nuts to 29 N-m (21 ft. lbs.).

1. Hitch bracket to bumper bracket nuts, washers, and
bolts.
2. Support to bumper nuts and bolts.
3. Hitch from the vehicle.
4. Chain bracket to bar assembly nut and bolt.
Chain bracket.
Support.
Bar assembly.
5. Bar assembly to hitch bracket nut and bolt.
Bar assembly.
Shim(s).
Hitch bracket.
~ l Install or Connect (Figure 28)

1. Hitch bracket to the bumper brackets with bolts,
washers, and nuts.
\$X\ Tighten
2. Bar assembly with shims (as required) to the hitch
bracket with bolts and nuts.
Assemble loosely.
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
1.
2.
3.
4.
5.
Bumper nuts and bolts.

Bumper.
Rear hitch nuts and washers.
Front bolts and washers.
Hitch from the vehicle.

1. Hitch to the vehicle.
2. Front bolts and washers.
Tighten
3. Rear washers and nuts.
Figure 29Weight Distribution Hitch

Tighten
* Nuts to 63 N-m (47 ft. lbs.).
4. Bumper to the vehicle with nuts and bolts.
Tighten
SPECIFICATIONS
BUMPER TORQUE SPECIFICATIONS
FASTENER
N m Ft. Lbs.
R/V M odels
Front Bumper
70
Bracket to Frame Rail N u ts ...................................................................................... .........95
Brace to Frame Rail B o lts ........................................................................................ .........50
37
Bracket to Bumper N uts......................................................................................................90
66
Brace to Bumper N u ts ............................................................................................... .........90
66
Rear Bumper (Utility Vehicle and Suburban)
70
Brace to Frame Rail N uts....................................................................................................95
70
Filler Panel to Support Bolts (Utility V e h ic le )..................................................... ........... 10
Filler Panel to Support Bolts (Suburban)................................................................ .........2.8
Filler Panel Bracket N u ts ....................................................................................................41
30
30
Brace to Bum per N u ts ............................................................................................... .........41
Rear Bumper (Regular Cab, Bonus Cab, Crew Cab)
70
Brace to Frame Rail N uts....................................................................................................95
70
Gravel Deflector N u ts ................................................................................................. .........10
Bumper to Bracket N uts......................................................................................................90
66
Brace to Bumper N u ts ............................................................................................... .........90
66
Rear Step Bumper
Bracket Reinforcement N u t s .............................................................................................70
52
52
Bracket to Brace N u t s ............................................................................................... .........70
Bumper to Brace N u ts ............................................................................................... .........70
52
Bumper to Bracket N uts......................................................................................................70
52
License Plate Bracket to Bum per N u ts................................................................................29
21
Trailer Hitch (Utility Vehicle and Suburban)
Bracket to Frame N u ts ............................................................................................... .........70
52
Bar Assembly to Bracket B o lt ...........................................................................................95
70
52
Bar Assembly to Support N u t ...........................................................................................70
Support to Bum per N u t s ....................................................................................................33
24
Weight Distribution Hitch
Suburban
Hitch to Vehicle Rear B o lts ...................................................................................... .........95
70
Hitch to Vehicle Front N u ts ...................................................................................... .........70
52
Utility Vehicle
Hitch to Vehicle Rear B o lts ...................................................................................... .........73
54
Hitch to Vehicle Front B o lts ...................................................................................... .........70
51
P M odels
Front Bumper
Bumper to Frame N uts............................................................................................... .........47
35
70
Bracket to Bumper N uts..................................................... ....................................... .........47
35
Brace to Frame N u t s ................................................................................................. .........85
63
35
Front Bum per (FS3 Front Axle)
35
Bracket to Bumper N uts......................................................................................................47
35
Brace to Frame N u t s ................................................................................................. .........40
30
Bracket to Frame N u ts ............................................................................................... .........64
47
In. Lbs.
89
25
89
BUMPER TORQUE SPECIFICATIONS (CONT.)
FASTENER
G M odels
Front Bumper
Bracket to Bum per N uts..............................................................
Bracket to Guard B o lts................................................................
Bracket to Cross Sill B o lts .........................................................
Brace to Bum per N u ts ................................................................
Brace to Frame B o lts ..................................................................
Rear Bumper
Brace to Bumper Top Nuts.................................................
Brace to Bumper Lower N uts.....................................................
Bracket to Frame Bolts................................................................
Brace to Cross Sill B o lt s ............................................................
Bumper to Bracket N uts..............................................................
Bracket to Frame Bolts................................................................
Bracket to Bumper N uts..............................................................
License Plate Bracket N u ts ............................................................
Trailer Hitch
Hitch Bracket to Bumper Bracket N u t......................................
Bar Assembly to Chain Bracket N u t ........................................
Bar Assembly to Hitch Bracket B o l t ........................................
Support to Bumper N u t s ............................................................
Weight Distribution Hitch
Hitch to Vehicle B olts..................................................................
Hitch to Vehicle N u ts ..................................................................
Bumper to Vehicle N u ts..............................................................
Nm
Ft. Lb
.............................
.............................
.............................
.............................
.............................
29
41
41
29
41
21
30
30
21
30
.............................
.............................
.............................
.............................
.............................
.............................
.............................
.............................
30
30
41
41
29
68
68
29
22
22
30
30
21
50
50
21
.............................
.............................
.............................
.............................
24
68
68
29
18
50
50
21
.............................
.............................
.............................
70
63
29
52
47
21
2B-1
SECTION 2B
SH EET METAL
NOTICE: All hood latch fasteners are im portant attaching parts in that they could affect the perform ance of
vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one o f the
same part num ber o f w ith an equivalent part if replacement becomes necessary. Do not use a replacem ent
part o f lesser quality or substitute design. Torque values must be used as specified during reassem bly to
assure proper retention o f all parts.
CONTENTS
SUBJECT
PAGE
R/V M o d e ls ................................................................................................................................................................... 2B - 2
Hood R eplacem ent..................................................................................................................................................2 B - 2
Spring Assembly R eplacem ent.................................................... ....................................................................2B- 2
Hood Hinge R e p la ce m e n t.....................................................................................................................................2B - 2
Primary Hood Latch R e p la c e m e n t..................................................................................................................... 2B - 2
Secondary Hood Latch And Spring Replacem ent........................................................................................... 2B - 3
Hood Release Cable R e p lace m e n t..................................................................................................................... 2B - 3
Hood Ornament R eplacem ent. . ..........................................................................................................................2B - 4
Cowl Vent Grille Replacement.............................................................................................................................. 2B - 4
Grille And Molding R e p la c e m e n t........................................................................................................................2B - 5
Front Fender R e p lace m e n t................................................................. ............................................................. 2B - 6
Wheelhouse Panel Replacement..........................................................................................................................2B - 7
Rear Fender R eplacem ent.....................................................................................................................................2B- 8
Radiator Support R eplacem ent............................................................................................................................ 2B-10
Sheet Metal Unit R e p la ce m e n t............................................................................................................................ 2B-11
Sheet Metal A djustm ents.......................................................................................................................................2B-11
G M odels....................................................................................................................................................................... 2B-13
Hood Replacem ent..................................................................................................................................................2B-13
Hood Hinge R e p la ce m e n t....................................................................................... ............................................. 2B-13
Primary Hood Latch R e p la ce m e n t..................................................................................................................... 2B-13
Secondary Hood Latch And Spring Replacement............................................................... ............................2B-14
Hood Release Cable R e p lace m e n t..................................................................................................................... 2B-15
Cowl Vent Grille Replacement.............................................................................................................................. 2B-15
Grille Replacem ent..................................................................................................................................................2B-15
Front End Sheet Metal Cross Panel R e p la ce m e n t......................................................................................... 2B-17
Sheet Metal Vertical Support R eplacem ent...................................................................................................... 2B-17
Front End Panel Replacement.............................................................................................................................. 2B-17
Cab M ounts...................................................................................................................................................................2B-18
Cab Mount R eplacem ent................................................................................................................................ .... .2B-18
S p e cifica tio n s............................................................................................................................................................... 2B-23
Special T o o ls ............. .................................................................................................................................................2B-23
2B-2 SHEET METAL
R/V MODELS
SPRING ASSEMBLY
REPLACEMENT
1.
2.
3.
Raise and support the front of the hood.

Spring assembly to hood bolts (4).
Spring assembly to fender bolts (1).
Spring assembly from the vehicle.

1. Spring assembly to the vehicle.
2. Spring assembly to fender bolts (1).
Tighten
Bolts to 25 N-m (18 ft. lbs.)

Spring assembly to hood bolts (4).
Tighten
HOOD HINGE REPLACEMENT

|<~+| Remove or Disconnect (Figure 1)
Figure 1Hood Hinge Components
HOOD REPLACEMENT
Raise and support the hood at front and rear.

1. C owl ve n t g rille . R efer to C owl V e nt G rille
Replacement.
2. Hinge to hood bolts (5).
3. Hinge to cowl bolts (6).
4. Hinge from the vehicle.

1. Hinge to the vehicle.
2. Hinge to cowl bolts (6).
Tighten
Raise and support the hood at front and rear.

Place protective coverings over the cowl and the
fenders.
Mark the position of the hinge on the hood.
1. Spring assembly to hood bolts (4).
2. Hood hinge to hood bolts (5).

3. Hinge to hood bolts (5).
^X
Tighten

4. C ow l ve n t g rille . R efer to C ow l V e n t G ril
Repacement.
3. Hood from the vehicle.

1. Hood to the vehicle.
Align the hood with the previously made marks.
Tighten

3. Spring assembly to hood bolts (4).
PRIMARY HOOD LATCH

REPLACEMENT
Raise the hood.
1. Hood latch release cable from the latch. Refer to
Hood Release Cable Replacement.
2. Bracket to hood latch bolts (9).
3. Hood latch from the vehicle.
4. Bracket to radiator support bolts (10).
5. Bracket from the vehicle.
A djust
Tighten
Front hood bumpers, so that the top of the hood is

flush with the fenders.
SHEET METAL 2B-3
Figure 2Hood Primary Latch Components
1. Bracket to the radiator support.

2. Bracket to support bolts (10) loosely.
SECONDARY HOOD LATCH

AND SPRING REPLACEMENT
3. Primary hood latch to the bracket.

4. Latch to bracket bolts (9) loosely.
5. Hood latch release cable to the latch.
Adjust
NOTICE: For Steps 1 and 2 refer to Notice on
page 2B-1.
1. Hood latch bracket left and right until the striker in the
hood easily engages the primary latch.
Raise the hood.
Bracket to radiator support bolts to 27 N-m (20 ft.

lbs.).
2. Hood latch height so that when the hood is closed, the
hood is held securely against the front hood bumpers.
Mark this height.
Raise the hood.
Mark the position of the secondary hood latch on the

hood.
1. Secondary hood latch to hood bolts (18).
2. Secondary hood latch from the vehicle.
3. Spring from the hood.
Twist the spring from the reinforcement.

1. Spring to the hood.
Twist the spring into the reinforcement.
2. Secondary hood latch to the vehicle.
Tighten
HOOD RELEASE CABLE

REPLACEMENT
NOTICE: Refer to Notice on page 2C-1 of this

section.
Tighten
Bracket to hood latch bolts to 27 N-m (20 ft. lbs.).
If the cable is broken, release the hood by pressing the

prim ary latch tab on the right side of the lock
assembly. Use a rod to press the tab.
Raise the hood.
Cable from the primary latch.
2B-4 SHEET METAL
++
1. New cable to the vehicle.

2. Cable through the drivers side of the cowl.
Push the grommet into the drivers side of the
cowl.
3. Cable bolts through the cable handle, and into the air
vent bezel.
4. Cable through the wheelhouse retaining strap, and the
radiator support.
5. Cable to the primary latch.
HOOD ORNAMENT
REPLACEMENT
Raise hood.
1. Hood ornament nuts (21).
2. Hood ornament from the hood.
3. Seal from the hood.

3.
15.
16.
17.
H oo d
S p rin g
S e co n d a ry H oo d L atch
1. Hood seal to the ornament.

2. Hood ornament to the hood.
3. Hood ornament nuts (21).
18. B o lt
COWL VENT GRILLE

REPLACEMENT
B-07272
Figure 3Hood Secondary Latch Components
2.
3.
4.
5.
Insert a screwdriver into the clip, and lift the

cable from the lock. Then, carefully pry the cable
grommet from the lock flange.
Cable from the radiator support, and the wheelhouse
retaining strap.
Grommet from the cowl.
Cut the grommet down to the cable casing on the
engine side of the cowl.
Push the cable and grommet through the cowl.
Cable handle to air vent bezel bolts.
Cable from the vehicle.
11.
13.
14.
19.
20.
1. Wiper arms.
2. Cowl vent grille panel screws.
3. Cowl vent grille plastic fasteners from the windshield
frame.
4. Cowl vent grille from the vehicle.
P rim a ry H o o d L a tc h
C able
C ab le C lip
B o lt
S tra p
Figure 4Hood Release Cable
B-07276
SHEET METAL 2B-5

1. Cowl vent grille to the vehicle.
2. Cowl vent grille plastic fasteners to the windhsield
frame.
3. Cowl vent grille panel screws.
4. Wiper arms.
GRILLE AND MOLDING

REPLACEMENT
++
1. Lower radiator grille to grille bolt (39).

2. Radiator support to grille bolts (30).
3. Grille from the vehicle.
Slide the bottom of the grille from the vehicle,
and then lower the grille from the vehicle.
4. Headlamp bezels.
5. Headlamp assemblies.
6. Molding assembly to fender, radiator support, and
lower grille panel nuts (33, 34 and 37).
7. Molding assembly from the vehicle.
8. Right and left moldings from the upper and lower
moldings.
9. Clips from the moldings.
10. Lower radiator grille to fender bolts (38).
24. R e ta in e r
25. R e ta in e r
26. C o w l V e n t G rille Panel
27. N u t
28. B o lt
B-07269
Figure 6Cowl Vent Grille Components
2B-6 SHEET METAL
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
R a d ia to r G rille
B o lt
R a d ia to r S u p p o rt
B o lt
N ut
N ut
B o lt
S ide M o ld in g
N ut
B o lt
B o lt
B o lt
L ow er M o ld in g
L o w e r R a d ia to r G rille
U p p e r M o ld in g
44. C lip
42
B-07274
Figure 7Grille Components

11. Lower radiator grille to the sheet metal support bolts
(40).
FRONT FENDER REPLACEMENT

12. Lower radiator grille from the vehicle.
+ Install or Connect (Figure 7)

1. Lower radiator grille to the vehicle.
2. Lower radiator grille to the sheet metal support bolts
(40).
3. Lower radiator grille to fender bolts (38).
4. Upper molding to the radiator support with clips (44),
and nuts (33).
Assemble loosely.
5. Lower molding to the radiator support with clips (44),
and nuts (37).
1.
2.
3.
4.
5.
6.
7.
8.
Assemble loosely.
6. Right and left moldings to the fenders.
The moldings must butt against the upper and
lower moldings, and be joined to those moldings
by the clips.
7. Right and left molding nuts (34).
Tighten upper and lower molding nuts (33 and 37).
9. Headlamp bezels.
10. Grille to the vehicle.
Insert the top of the grille to the underside of the
radiator support, and then slide the bottom of the
grille into place.
11. Lower radiator grille to grille bolt (39).
12. Radiator support to grille bolts (30).
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Tool Required:
J-24595-B Door Trim Pad Remover.
Raise and support the hood.
Head lamp bezel.
Head lamp.
Right or left radiator grille molding nuts (34).
Upper and lower molding clip nuts (33 and 37).
Right or left radiator grille molding (36).
Lower radiator grille to fender bolts (38).
C ow l v e n t g rille . R efer to C ow l V e n t G rille
Replacement.
Hood spring assembly. Refer to Spring Assembly
Replacement.
Radiator support to fender bolts (119).
Wheelhouse panel to shield bolts.
Shield to underbody retainers using J-24595-B.
Shield from the vehicle.
Wheelhouse panel to fender bolts (50).
Lower door pillar to fender bolt (45) and shim(s) (46).
Fender to cowl bolt (47) and shim(s) (46).
Open the front door.
Upper fender to door pillar bolt (48) and shim(s) (46).
Fender from the vehicle.
Insulator from the fender.
- Install or Connect (Figures 8 and 9)

1. Insulator to the fender.
2. Fender to the vehicle.
SHEET METAL 2B-7

Tighten
7. Wheelhouse to fender bolts (50).
Wheelhouse to fender bolts (50) to 17 N m (13 ft.

lbs.).
Lower door pillar to fender bolt to 43 N m (31 ft.
lbs.).
8. Shield to the vehicle.
9. Shield to underbody retainers.
10. Wheelhouse panel to shield bolts.
11
12
13.
14.
15.
16.
17.
18.
3. Upper fender to the door pillar bolt (48) and shim(s)

(46) as required.
WHEELHOUSE PANEL
REPLACEMENT
RIGHT PANEL REPLACEMENT
Assemble loosely.
4. Fender to cowl bolt (47) and shim(s) (46) as required.
Assemble loosely.
5. Lower door pillar to fender bolt (45) and shim(s) (46) as
required.
Assemble loosely.
6. Radiator support to fender bolts (119).
Fender to cowl bolt (47) to 43 N m (31 ft. lbs.).

Upper fender to door pillar bolt to 43 N m (31 ft.
lbs.).
Hood spring assembly. Refer to Spring Assembly
Replacement.
C owl ve n t g rille . R efer to C ow l V e n t G rille
Replacement.
Lower radiator grille to fender bolts (38).
Right or left radiator grille molding (36).
Upper and lower molding clip nuts (33 and 37).
Right or left radiator grille molding nuts (34).
Head lamp.
Head lamp bezel.
1.
2.
3.
4.
5.
6.
7.
8.
Jack handle.
Lug wrench.
Coolant recovery reservoir.
Air conditioning line retainers (if equipped).
Raise and support the vehicle.
Right front wheel.
Wheelhouse panel to radiator support bolts (49).
Wheelhouse panel to underbody shield bolts.
Wheelhouse panel reinforcement to underbody bolts
(52) and (53).
9. Wheelhouse panel to fender bolts (50).
10. Wheelhouse panel from the vehicle.
Slide the panel forward to clear the lower back
side of the fender well.
Tilt the wheelhouse panel out of the vehicle.

1. Wheelhouse panel to the vehicle.
Tilt the wheelhouse panel into the vehicle.
Slide the panel into position.
Tighten
Figure 9Wheelhouse Panel Attachment

3. Wheelhouse panel reinforcement to underbody bolts
(52) and (53).
2B-8 SHEET METAL
Tighten
Bolts (52) to 17 N m (13 ft. lbs.).

Bolt (53) to 47 N-m (35 ft. lbs.).
Tighten
6.
7.
8.
9.
10.

Right front wheel.
Lower the vehicle.
Air conditioning line retainers (if equipped).
Coolant recovery reservoir.
Lug wrench.
Jack handle.
LEFT PANEL REPLACEMENT

1.
2.
34.
5.
6.
7.
8.
9.
Jack.
Windshield washer fluid reservoir.
Wiring harness.
Hood release cable.
Air conditioning hose bracket (if equipped).
Left front wheel.
(52) and (53).
11. Wheelhouse panel from the vehicle.
Slide the panel forward to clear the lower back
side of the fender well.
Tilt the wheelhouse panel out of the vehicle.
-n - Install or Connect (Figure 9)

Wheelhouse panel to the vehicle.
Tilt the wheelhouse panel into the vehicle.
Slide the panel into position.
Wheelhouse panel to fender bolts (50).

52) and (53).
Tighten
Bolt (52) to 17 N-m (13 ft. lbs.).
Bolt (53) to 47 N m (35 ft. lbs.).
Tighten
6.
7.
8.
9.
10.
11.

Left front wheel.
Lower the vehicle.
Air conditioning hose bracket (if equipped).
Hood release cable.
Wiring harness.
Windshield washer fluid reservoir.
Jack.
REAR FENDER REPLACEMENT

STEPSIDE MODEL FENDER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Parking lamp wiring from the fender.

Brace to fender bolts (59).
Side panel to fender bolts (56).
Side panel to brace bolt (56).
Brace (58).
Cross sill to brace bolt (63).
Brace (62).
Sealer from the fender and the side panel.
-4- Install o r Connect (Figure 10)

1. A medium bodied sealer onto the fender to side panel
flange.
2. Brace (62).
3. Cross sill to brace bolt (63).
Assemble loosely.
4. Brace (58) to the vehicle.
5. Side panel to brace bolt (56).
Assemble loosely.
7. Side panel to fender bolts (56).
Assemble loosely.
8. Brace to fender bolts (59).
Tighten
Brace to fender bolts to 17 N-m (13 ft. lbs.).
Side panel to fender bolts to 10 N-m (7 ft. lbs.).
Cross sill to brace bolt to 17 N m (13 ft. lbs.).
9. Parking lamp wiring to the fender.
Clean excess sealant from the fender.
DUAL REAR WHEEL MODEL FENDER

REPLACEMENT
0
1.
2.
3.
4.
5.
6.

Parking lamp wiring from the fender.
Fender to brace bolts (71).
Fender to side panel bolts (72 and 69) and nuts (68).
Side panel to fender nuts (66).
Sealer from the side panel and fender.

1. A medium bodied sealer onto the fender to side panel
flange.
3. Side panel to fender nuts (66).
Assemble loosely.
4. Fender to side panel bolts (72 and 69) and nuts (68).
Assemble ioosely.
5. Fender to brace bolts (71).
All of the nuts and bolts to 17 N m (13 ft. lbs.).

Parking lamp wiring to the fender.
Clean excess sealant from the fender.
SHEET METAL 2B-9
Figure 10Stepside Rear Fender Attachment
Figure 11Dual Rear Fender Attachment
2B-10 SHEET METAL
73.
74.
75.
76.
77.
78.
79.
80.
81.
B olt
W asher
R etainer
C ushion - Upper
Bracket
C ushion - Lower
R etainer
N ut
R adiator S upport
B-07280
Figure 12Radiator Support Mounting
RADIATOR SUPPORT
REPLACEMENT
1. Radiator from the vehicle.
Refer to ENGINE COOLING (SEC. 6B).
2. Air conditioning condenser from the vehicle.
Refer to AIR CONDITIONING (SEC. 1B).
3. Battery.
Refer to ENGINE ELECTRICAL (SEC. 6D).
4. Headlamp and parking lamp wires from the lamps.
5. Headlamp and parking lamp wiring harness from the
radiator support.
6. Headlamp bezels.
8. Ground wires from the radiator support.
9. Fuel vapor canister from the radiator support.
10. Air cleaner inlet from the radiator support.
11. Primary hood latch bracket to the radiator support
bolts.
13. Lower radiator grille panel from the vehicle.
14. Sheet metal support to radiator support bolts.
15. Sheet metal support from the vehicle.
16. Radiator support to fender bolts (119) (figure 8).
17. Wheelhouse panel to radiator support bolts (49) (figure
9).
18. Radiator support to frame nuts (80), lower retainers
(79), lower cushions (78), upper cushions (76), retainers
(75), bolts (73), and washers (74).
19. Radiator support from the vehicle.
Tilt the radiator support to the rear, and lift it up

and out of the vehicle.

Radiator support to the vehicle.
Lower the radiator support into the vehicle, and
tilt it into position.
2. Radiator support to frame washers (74), bolts (73),
retainers (75), upper cushions (76), lower cushions
(78), lower retainers (79), and frame nuts (80).
Assemble loosely.
Wheelhouse panel to radiator support bolts (49) (figure
9).

4. Radiator support to fender bolts (119) (figure 8).

Sheet metal support to the vehicle.
Sheet metal support to radiator support bolts.
Tighten
Radiator support to frame nuts (80) to 47 N-m (35
ft. lbs.).
7. Lower radiator grille panel to the vehicle.
8. Grille to the vehicle.
9. Primary hood latch bracket to the radiator support
bolts.
SHEET METAL 2B-11

Adjust
Hood latch left or right so that the hood properly
engages the hood latch.
Tighten
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Bracket to radiator support bolts to 27 N m (20 ft.

lbs.).
Air cleaner inlet to the radiator support.
Fuel vapor canister to the radiator support.
Ground wires to the radiator support.
Headlamp assemblies.
Headlamp bezels.
Headlamp and parking lamp wiring harness to the
radiator support.
Headlamp and parking lamp wires to the lamps.
Battery.
Air conditioning condenser.
Radiator.
+ Install or Connect
1. Sheet metal assembly.
With the aid of a helper, lift the sheet metal onto
the chassis.
2. Radiator support to frame washers (74), bolts (73),
retainers (75), upper cushions (76), lower cushions
(78), lower retainers (79), and nuts (80) (figure 12).
3. Lower fender to door pillar bolts (45) (figure 8).
4.
5.
6.
7.
Bolt to 43 N m (31 ft. lbs.).

8. Fender to cowl bolts (47).
Tighten
Wheelhouse panel to fender bolts (50) (figure 9).
SHEET METAL UNIT

REPLACEMENT
Tool Required:
J-24595-B Door Trim Pad Remover.
1. Hood.
Refer to Hood Replacement earlier in this
section.
2. Battery.
3. Radiator.
4. Air conditioning condenser.

Shield to the vehicle.
Shield to underbody retainers.
Wheelhouse panel to shield bolts.
Upper fender to door pillar bolt (48) (figure 8).
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Wheelhouse panel to fender bolts to 17 N-m (13

ft. lbs.).
Bumper.
Refer to FRAME AND BUMPERS (SEC. 2A).
Air cleaner inlet to the radiator support.
Fuel vapor canister to the radiator support.
Ground wires to the radiator support.
Headlamp and parking lamp wiring harness to the
radiator support.
Head lamp and parking lamp wires to the lamps.
Air conditioning condenser.
Radiator to the vehicle. Refer to ENGINE COOLING
(SEC. 6B).
Battery to the vehicle.
Hood to the vehicle.
5 . H e a d la m p a n d p a rk in g la m p w ire s fr o m th e la m p s .
6. Headlamp and parking lamp wiring harness from the

radiator support.
7. Ground wires from the radiator support.
8. Fuel vapor canister from the radiator support.
9. Air cleaner inlet from the radiator support.
Refer to FRAME AND BUMPERS (SEC. 2A).
11. Wheelhouse panel to fender bolts (50) (figure 9).
12. Fender to cowl bolts (47) (figure 8).
13. Upper fender to door pillar bolt (48).
14. Wheelhouse panel to shield bolts.
15. Shield to underbody retainers using J-24595-B.
16. Shield from the vehicle.
17. Lower fender to door pillar bolt (45).
18. Radiator support to frame nuts (80), lower retainers
(79), lower cushions (78), upper cushions (76), retainers
(75), bolts (73), and washers (74) (figure 12).
19. Sheet metal assembly.
With the aid of a helper, lift the sheet metal from
the chassis.
SHEET METAL ADJUSTMENTS

In order to have the proper operation and appearance
of sheet metal components, it is important that certain fits
and gaps between components be maintained. The gaps
given in this procedure are suggested as the best
alignm ent for these components (figure 13).
In aligning sheet metal, it is best to start with the
rearmost component, and work forward.
1. Starting with the fenders, align the rear edge of each
fender to the rocker panel, and the door. The gap
between these components should be 5 mm 2.3 mm
(0.19-inch 0.09-inch). This adjustment should be
accom plished by m oving the fender forward or
rearward. The surface of the fender should be flush
with the rocker panel and the door. Add or remove
shims to perform this adjustment.
2. Align the fender to the cowl vent grille to obtain a gap
of 4.6 mm 1 mm (0.18-inch 0.03-inch). The surface
of the cowl vent grille should be flush with the fender
surface.
2B-12 SHEET METAL
82.
83.
84.
85.
86.
87.
A.
B.
C.
D.
E.
F.
Hood
Fender
Door
Cow l V ent G rille
R ocker Panel
R adiator S upport Upper Panel
Flush Fit
Flush 1 m m (0.03-inch)
Flush +0.00 mm or -1.5 mm ( + 0.00-inch or -0.06-inch)
4.6 mm 1 mm (0.18-inch 0.03-inch)
8 mm 1 mm (0.31-inch 0.03-inch)
5 mm 2.3 mm (0.19-inch 0.09-inch)
F -0 2 3 4 8
Figure 13Sheet Metal Gap Specifications
SHEET METAL 2B-13

3. Align the hood with the cowl vent grille, so that there is
a gap of 8 mm 1 mm (0.31-inch 0.03-inch) between
the rear edge of the hood and the front edge of the
cowl vent grille. The hood surface should be flush with
the cowl vent grille surface within + 0.0-1.5 mm (+ 0.00
-0.06-inch).
4. Align the left and right edges of the hood so that a gap
of 4.6 mm 1 mm (0.18-inch 0.03-inch) exists
between the hood and the fenders. The hood surface
should be fiush with the fender surface within +0.0,
-1.5 mm ( + 0.00 -0.06-inch). If this gap is difficult to
obtain, and the hood appears to be cocked in between
the fenders, the radiator support may need to be
shifted. By shifting the radiator support, the entire front

end sheet metal can be aligned as a unit. Loosen the
support to the frame bolts, and shift the radiator
support to obtain the proper gaps. Then, while holding
the support in position, retighten the radiator support to
frame bolts.
5. Align the front face of the hood to obtain a gap of 4.6
mm 1 mm (0.18-inch + 0.03-inch) between the hood
and the radiator support upper panel. The hood
bumpers on the top of the radiator support should be
adjusted to give the proper support to hood gap. The
surface of the hood should be flush with the radiator
support upper panel (not the grille molding).
G MODELS
1. Hood to the vehicle.
Align the hood with the previously made marks.
Tighten
Remove the protective coverings, and lower the hood.
HOOD HINGE REPLACEMENT
++
Raise and support the hood. Also support the rear

corner of the hood.
Mark the position of the hinge on the hood and the
cowl.
2. Hood hinge to cowl bolts (90).
3. Hood hinge from the vehicle.

1.
2.
3.
88. H o o d
89. B o lt
90. B o lt
Hood hinge to the vehicle.

Hood hinge to cowl bolts (90).
Hood hinge to hood bolts (89).
Align the hinge with the previously made marks.
B-07273
Figure 14Hood Hinge Components
HOOD REPLACEMENT
Raise and support the hood. Place a protective
covering over the fenders, and the cowl vent grille.
Mark the position of the hinges on the hood.
PRIMARY HOOD LATCH

REPLACEMENT
1. Hood latch release cable from the latch.
2. Bracket to hood latch bolts (94).

3. Hood latch from the vehicle.
4. Bracket to the sheet metal cross panel bolts (91).
2. Hood from the vehicle.
5. Bracket from the vehicle.
2B-14 SHEET METAL
Tighten
Bracket to radiator support bolts to 27 N m (20 ft.

lbs.)
92. Primary Latch

93. Bracket
94. Bolt
B-07281
2. Hood latch height so that when the hood is closed, the

hood is held securely against the front hood bumpers.
Tighten
Figure 15Primary Hood Latch Attachment
Bracket to hood latch bolts to 27 N m (20 ft. lbs.).
Adjust
Front hood bumpers, so that the top of the hood is
flush with the fenders.
"" Install or Connect (Figure 15)

1. Bracket to the sheet metal cross panel.
2. Bracket to cross panel bolts (91) loosely.
3. Primary hood latch to the bracket.
4. Latch to bracket bolts (94) loosely.
5. Hood latch release cable to the latch.
NOTICE: For Steps 1 and 2 refer to Notice on

page 2B-1.
Adjust
1. Hood latch bracket left and right until the striker in the
hood easily engages the primary latch.
SECONDARY HOOD LATCH

AND SPRING REPLACEMENT
< - | Remove or Disconnect (Figure 16)

Mark the position of the secondary hood latch on the
hood.
2. Secondary hood latch from the vehicle.
3. Spring from the hood.
Twist the spring from the reinforcement.

1. Spring to the hood.
Twist the spring into the reinforcement.
2. Secondary hood latch to the vehicle.
Tighten
SHEET METAL 2B-15
Figure 17Hood Release Cable Attachment
COWL VENT GRILLE

REPLACEMENT
HOOD RELEASE CABLE

REPLACEMENT
If the cable is broken, release the hood by pressing the

prim ary latch tab on the right side of the lock
assembly. Use a rod to press the tab.

Cable from the primary latch.
Insert a screwdriver into the clip, and lift the
cable from the lock. Then, carefully pry the cable
grommet from the lock flange.
Cable from the sheet metal cross panel clip.
Grommet from the cowl.
Cut the grommet down to the cable casing on the
engine side of the cowl.
Push the cable and the grommet through the
cowl.
Cable handle to dash screws.
Cable from the vehicle.
1. Windshield wiper arms.
2. Cowl vent grille to cowl bolts (104) and screws (103).

3. Cowl vent grille from the vehicle.
4. Cowl seal from the vehicle.
++
1. Cowl seal to the vehicle.

2. Cowl vent grille to the vehicle.
3. Cowl vent grille to cowl bolts (104) and screws (103).
4. Windshield wiper arms.
GRILLE REPLACEMENT
1. Headlamp bezels.
New cable to the vehicle.
2. Sheet metal cross panel to grille bolts.
Cable through the drivers side of the cowl.

Push the grommet into the drivers side of the
cowl, and then push the insert into the grommet.
Cable handle to dash screws.
Cable into the sheet metal cross panel clip.
Cable to the primary latch.
3. Grille to lower front end panel bolts.

5. Sheet metal to upper and lower radiator grille molding
nuts (110 and 112).
6. Upper and lower radiator grille moldings from the
vehicle.
2B-16 SHEET METAL
102.
103.
104.
105.
106.
C ow l V e n t G rille Panel
Screw
B o lt/S cre w
N ut
Seal
F-07286
Figure 18Cowl Vent Grille Components
109. F ro n t End S h ee t M e ta l C ro s s Panel

110. N u t
111. U p p e r M o ld in g
112. N ut
113. L ow er M o ld in g
E
Figure 19Radiator Grille
Figure 20Radiator Grille Molding Attachment
SHEET METAL 2B-17

+- Install or Connect (Figure 21)
1. Sheet metal cross panel to the vehicle.

2. Sheet metal cross panel to the headlamp bezel
support bolts.
Assemble loosely.
3. Sheet metal cross panel to the radiator support baffle
panel bolts.
Assemble loosely.
4. Sheet metal cross panel to the hood latch bracket bolts
(91).
Assemble loosely.
5. Sheet metal cross panel to the fender bolts (114).
Tighten
Bolts in steps 2 through 5 to 27 N m (20 ft. lbs.).
Upper radiator mounts.
Upper radiator mount to sheet metal cross panel bolts.
Air intake snorkel.
Primary hood latch. Refer to Primary Hood Latch
Replacement.
10. Grille. Refer to Grille Repalcement.
11. Headlamp bezels.
Lower the hood.
6.
7.
8.
9.
SHEET METAL VERTICAL

SUPPORT REPLACEMENT
109. Front End Sheet M etal C ross Panel

114. B olt
B-07289
Figure 21-Front End Sheet Metal Cross

Panel Attachment
+- Install or Connect (Figures 19 and 20)
Upper and lower radiator grille moldings to the vehicle.
Sheet metal to upper and lower radiator grille molding
nuts (110 and 112).
Grille to the vehicle.
Grille to lower front end panel bolts.
Sheet metal cross panel to grille bolts.
Headlamp bezels.
Lower the hood.
FRONT END SHEET METAL

CROSS PANEL REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Headlamp bezels.
Grille. Refer to Grille Replacement.
Primary hood latch. Refer to Primary Hood Latch
Replacement.
Air intake snorkel.
Upper radiator mount to sheet metal cross panel bolts.
Upper radiator mounts.
Sheet metal cross panel to fender bolts (114).
Sheet metal cross panel to the hood latch bracket bolts
(91).
Sheet metal cross panel to radiator support baffle
panel bolts.
Sheet metal cross panel to the headlamp bezel
support bolts.
Sheet metal cross panel from the vehicle.

1.
2.
3.
4.
5.

Vertical support to sill bolts (17).
Front end panel to vertical support bolts (120).
Sheet metal cross panel to vertical support bolts (115).
Vertical support from the vehicle.

1. Vertical support to the vehicle.
2. Sheet metal cross panel to vertical support bolts (115).

3. Front end panel to vertical support bolts (120).
Tighten
4. Vertical support to sill bolts (117).
Tighten
5. Grille. Refer to Grille Replacement.
FRONT END PANEL

REPLACEMENT
1.
2.
3.
4.
5.
6.
Headlamp bezels.
Front end panel to headlamp bezel support bolts (118).
Front end panel to sill bolts (121).
Front end panel to vertical support bolts (120).
Front end panel from the vehicle.
2B-18 SHEET METAL
121
116. Sheet Metal
V ertical Support
117. Front End Panel
118. Bolt
120. Bolt
121. Bolt
B-07282
Figure 23Front End Panel Attachment

1. Front end panel to the vehicle.
2. Front end panel to vertical support bolts (120).
Assemble loosely.
3. Front end panel to sill bolts (121).
4. Front end panel to headlamp bezel support bolts (118).
5. Grille. Refer to Grille Replacement.
6. Headlamp bezels.
Tighten
Figure 22Front End Sheet Metal

Vertical Support
CAB MOUNTS
CAB MOUNT REPLACEMENT
When changing cab mounts, it is important
support the frame while changing the mount.
mount is to be changed, the entire side on
mount is placed must be lowered enough
clearance for the mount.
to properly
If only one
which the
to provide

Raise the vehicle slightly on the hoist.
Place jack stands under the body on the side of the
vehicle where the m ounts will be replaced.
1. Bolt (279), retainer (278), and lower cushion (277) or
nut (283), washer (277), cushion (277) and spacer
(281).
Lower the hoist enough to leave the body supported

by the jacks.
2. Shim (275) and upper cushion (276).
-4- Install or Connect (Figures 24 through 26)
1. Upper cushion (276) and shim (275).
Raise the frame on the hoist slightly.
2. Lower cushion (277), retainer (278) and bolt (279) or
spacer (281), cushion (277), washer (277) and nut
(283).
Remove the jacks.
&
Tighten

Lower the hoist.
SHEET METAL 2B-19
279
277.
278.
279.
280.
L ow er C u s h io n
R e ta in e r
B o lt
W eld N u t
%
A. M o u n t No. 1
B. M o u n t No. 2
C. M o u n t No. 3
F-02294
Figure 24Cab Mounts for the R/V Chassis with a Bonus or Crew Cab
2B-20 SHEET METAL
279. B o lt
280. W eld N ut
F-02295
F igure 25Cab M ounts fo r th e R/V C hassis w ith a R egular Cab
SHEET METAL 2B-21
275
279
279
B
275.
276.
277.
278.
279.
280.
281.
282.
283.
S h im
U p p e r C u s h io n
L o w e r C u s h io n
R e ta in e r
B o lt
W eld N u t
A.
S p a ce r
B.
W a sh e r
C.
N ut
D.
M ount
M ount
M ount
M ount
N o.
N o.
No.
N o.
276
1
2
3
4
F-02293
Figure 26Cab Mounts for the R/V Pickup
2B-22 SHEET METAL
280
c
275.
276.
277.
278.
279.
280.
283.
S h im
R e ta in e r
B o lt
W eld N u t
N ut
A.
B.
C.
D.
E.
F.
M ount
M ount
M ount
M ount
M ount
M ount
N o.
N o.
N o.
N o.
N o.
N o.
1
2
3
4
5
6
F-02292
F-02292
Figure 27Cab Mounts for the Suburban
SHEET METAL 2B-23
SPECIFICATIONS
N-m
TORQUE
Ft. Lbs.
R/V Models
Hood Hinge to Hood B o lts ..........................................................................................................................25
Hood Hinge to Cowl B olts................................................................................................................... .........43
Spring Assem bly to Hood B o lts .................................................................................................................25
Spring Assem bly to Fender B o lts ...............................................................................................................25
Primary Hood Latch Bracket to Radiator Support B o lts .............................................................. .........27
Bracket to Primary Hood Latch B o lts ............................................................................................... .........27
Secondary Hood Latch to Hood B o lts ......................................................................................................27
Sheet Metal Support to Radiator Support B o lt s ........................................................................... .........17
Radiator Support to Fender B o lts...............................................................................................................17
Radiator Support to Frame N uts.................................................................................................................47
W heelhouse to Fender B o l t ........................................................................................................................43
Fender to Cowl B o lt.............................................................................................................................. .........43
Upper Fender to Door Pillar B o lt ...............................................................................................................43
W heelhouse Panel Reinforcement to Underbody Bolts (52 )....................................................... .........17
(53 )....................................................... .........47
W heelhouse to Radiator Support B o lts ....................................................................................................17
Stepside Models
Brace to Rear Fender B o lt s .............................................................................................................. ......... 17
Side Panel to Rear Fender B o lts ............................................................................................................... 10
Side Panel to Brace B o lts ................................................................................................................... ......... 10
Fleetside Models
All Rear Fender to Side Panel Bolts, and N u ts ............................................................................. ......... 17
G Models
Hood Hinge to Hood B o lts .......................................................................................................................... 17
Primary Hood Latch Bracket to Radiator Support B o lts .............................................................. ......... 27
Bracket to Primary Hood Latch B o lts ............................................................................................... ......... 27
Secondary Hood Latch to Hood B o lts ............................................................................................. ......... 27
Sheet Metal Cross Panel to Headlamp Bezel Support B o lts ..................................................... ......... 27
Sheet Metal Cross Panel to Radiator Support Baffle Panel B o lt s ............................................ ......... 27
Sheet Metal Cross Panel to Hood Latch Bracket B o lts ................................................................ ......... 27
Sheet Metal Cross Panel to Fender B o lts ...................................................................................... ......... 28
Sheet Metal Cross Panel to Vertical Support B o lts ................................................................................ 27
Front End Panel to Vertical Support B o lts ...................................................................................... ......... 18
Vertical Support to Sill B o lts........................................................................................................................ 10
Front End Panel to Vehicle B o lts ............................................................................................................... 18
Cab Mounts
Cab Mount B o lts .................................................................................................................................. ......... 75
Cab Mount N u t s .................................................................................................................................. ......... 47
18
32
18
18
20
20
20
13
13
35
31
31
31
13
35
13
13
7
7
13
13
20
20
20
20
20
20
20
20
13
7
13
55
35
SPECIAL TOOLS
1.
J-24595-B
1. D oo r Trim Pad R em over
F-02347
2B-24 SHEET METAL
3A-1
SECTION 3
STEERIN G, SUSPENSION,
W HEELS AND TIR ES
CONTENTS
SUBJECT
PAGE
Front End A lignm ent.......................................................................................................................................................3A-1

Steering L inkage...........................................................................................................................................................3B1-1
Manual Steering......................................... ................................................................................................................... 3B2-1
Power S te e rin g ............................................................................................................................................................. 3B3-1
Steering C o lu m n ...........................................................................................................................................................3B4-1
Front Suspension And A x le .......................................................................................................................................... 3C-1
Rear Suspension............................................................................................................................................................. 3D-1
Wheels And T ir e s ...........................................................................................................................................................3E-1
SECTION 3A
FRONT END ALIGNMENT

The following Notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the term inology: NOTICE : See Notice on page 3A-1 on this section.
NOTICE: Front end alignm ent fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in m ajor repair expense. They must be replaced with one o f the same
part num ber or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part o f lesser
quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention
o f all parts.
CONTENTS
SUBJECT
PAGE
Description....................................................................................................................................................................... 3A-2
Definition of T e rm s ............................................................ .....................................................................................3A-2
Diagnosis of Front End Alignm ent.............................................................................. ................................................. 3A-3
On-Vehicle S e rvice .........................................................................................................................................................3A-3
Inspection..................................................................................................................................................................... 3A-3
Front End Alignment Requirements..........................................................................................................................3A-3
Alignment Adjustments.............................................................................................................................................. 3A-4
S pe cifica tio ns.................................................................................................................................................................3A-6
3A-2 FRONT END ALIGNMENT
DESCRIPTION
Side View
Front View
A
C
D
E
m in u s B . . .C a m b e r (Inches)
. .C a m b e r (D e gre es P o sitive)
. . .C a ste r (D e gre es P o sitive)
m in u s F ..........Toe-In (Inches)
B-07371
Figure 1Caster-Camber-Toe-ln
Front End Alignm ent refers to the angular relation
ship between the front wheels, the front suspension atta
ching parts and the ground.
Proper front end alignm ent must be maintained in order
to insure efficient steering, good directional stability and
to prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber, and axle caster (Figure 1).
DEFINITION OF TERMS
CAMBER
Camber is the inward or outward tilting of the front
wheels from the vertical. When the wheels tilt outward at
the top, the camber is positive ( + ). When the wheels tilt
inward at the top, the camber is negative (). The amount
of tilt measured in degrees from the vertical is called the
camber angle. Camber is designed into the front axle
a ss e m b ly of all fo u r-w h e e l d rive v e h ic le s and is
non-adjustable.
If camber is extreme or unequal between the wheels,
improper steering and excessive tire wear will result.
Negative camber causes wear on the inside tire, while
positive camber causes wear to the outside.
CASTER (Figure 1)
Caster is the tilting of the wheel axis either forward or
backward from the vertical (when viewed from the side of
the vehicle). A backward tilt is positive ( + ) and a forward
tilt is negative ().
On the short and long arm type suspension you cannot
see a caster angle without a special instrument, but if you
look straight down from the top of the upper control arm to
the ground, the ball joints do not line up (fore and aft)
when a caster angle other than 0 degree is present. With
a positive angle, the lower ball joint would be slightly
ahead (toward the front of the vehicle) of the upper ball
joint center line. Caster is designed into the front axle
a ssem bly on all fo u r-w h e e l d rive ve h icle s, and is
non-adjustable.
TOE-IN
Toe-in is the turning of the front wheels. The actual
amount of toe-in is normally a fraction of a degree. Toe-in
is measured from the center of the tire treads or from the
inside of the tires. The purpose of toe-in is to insure
parallel rolling of the front wheels and to offset any small
deflections of the wheel support system which occurs
when the vehicle is rolling forward. Incorrect toe-in results
in excessive toe-in and unstable steering. Toe-in is the last
alignment to be set in the front end alignm ent procedure.
FRONT END ALIGNMENT 3A-3
DIAGNOSIS OF FRONT END ALIGNMENT

PROBLEM
CORRECTION
POSSIBLE CAUSE
Noisy Front End
1. Worn tie rod ends.

2. Loose suspension bolts.
3. Lack of proper lubrication.
4. Loose shock absorbers or worn bush
ings.
5. Loose stabilizer bar.
Wheel Bounce
1. Refer to
3E).
2. Replace
3. Replace
4. Refer to
3E).
5. Refer to
3E).
1. Tire and wheel out of balance.

2. Blister or bump on the tire.
3. Im proper shock absorber action.
4. Excessive wheel or tire run-out.
5. Tire Lead.
Excessive Tire Wear
1. Replace ends.
2. Refer to FRONT SUSPENSION (SEC.
3C).
3. Refer to MAINTENANCE AND LUBRI
CATION (SEC. OB).
4. Tighten bolts and/or replace the bush
ings.
5. Tighten
1. Incorrect wheel alignment.

2. Failure to rotate tires.
3. Faulty shock absorbers.
4. Improper tire pressure.
5. Overloaded or improperly loaded vehi
cle.
6. Broken or sagging springs.
WHEELS AND TIRES (SEC.

the tire.
the shock absorber.
W HEELS AND TIRES (SEC.
W HEELS AND TIRES (SEC.
1. Align the wheels.

2. Refer to W HEELS AND TIRES (SEC.
3E).
3. Replace shock absorber.
4. Refer to W HEELS AND TIRES (SEC.
3E).
5. Avoid overloading vehicle.
6. Replace springs.
ON-VEHICLE SERVICE
INSPECTION
9. Alignm ent equipm ent. Follow the m anufacturers

instructions.
B efore m aking any a d ju stm e n ts a ffe ctin g caster,

cam ber or toe-in, the following front end inspection should
be made:
10. Level of the vehicle. The vehicle must be on a level

surface fore and aft and transversely.
Inspect (Figure 2)
1. Tires for proper inflation pressure. Refer to WHEELS
AND TIRES (SEC. 3E).
2. Front wheel bearing for proper adjustment. Refer to
FRONT SUSPENSION (SEC. 3C.).
3. Ball joints, tie rod ends, and relay rods. If excessive
looseness is noted, correct before adjusting. Refer to
STEERING LINKAGE (SEC. 3B1).
4. Wheels and tires for run-out. Refer to WHEELS AND
TIRES (SEC. 3E).
5. D im e n sio n B C in (fig u re 2). If not w ith in
specifications, the correction must be made before
adjusting caster.
6. Steering gear for looseness at the frame.
7. Shock absorbers for leaks or any noticeable noise.
Refer to FRONT SUSPENSION (SEC. 3C).
8. C ontrol arms or s ta b ilize r bar attachm ents for
looseness. Refer to FRONT SUSPENSION (SEC. 3C).
FRONT END ALIGNMENT

REQUIREMENTS
Satisfactory vehicle operation may occur over a wide
range of front end alignm ent settings. If the settings vary
beyond certain tolerances, adjustm ents are advisable.
The Specifications at the back of this section is a
guideline for vehicle diagnosis or for repairs.
Set the front end alignm ent to specifications w hile the
vehicle is in its normally loaded condition. Vehicles
w hich are consistently operated with heavy loads
should have toe-in adjusted with the vehicle under

heavy load. This procedure should result in longer tire
life.
A. D im e n s io n B C
B. J o u n c e B u m p e r B ra c k e t
C. C ro s s m e m b e r
B A
D. A DOWN IN REAR frame angle must be SUB
TRACTED from a POSITIVE caster reading.
F. A DOWN IN REAR frame angle must be ADDED

to a NEGATIVE caster reading.
r-
HORIZONTAL
FRAME ANGLE = W
HORIZONTAL
v FRAME ANGLE
\ = 1/2 DOWN
DOWN
CASTER ANGLE READING = + (2-V a )

ACTUAL (CORRECTED) CASTER ANGLE = + (1)
C A S T E R A N G L E R E A D IN G = (-Va )
A C T U A L (C O R R E C TE D ) C A S T E R A N G L E = (1-3/4)
G. An UP IN REAR frame angle must be SUBTRACTED

from a NEGATIVE caster reading.
E. A UP IN REAR frame angle must be ADDED to a

POSITIVE caster reading.
HORIZONTAL
HORIZONTAL
FRAME ANGLE
= 1 1/4 UP
FRAME ANGLE = 1 UP
CASTER ANGLE READING = (1/4)

CASTER ANGLE READING = + (2)

B-07373
Figure 2Determining Caster
ALIGNMENT ADJUSTMENTS
A normal shim pack will leave at least two threads of
the bolt exposed beyond the nut. If two threads cannot be
obtained, check for control arms and related parts. The
difference between front and rear shim packs must not
exceed 7.62 mm (0.03 inch). Front shim pack must be at
least 2.54 mm (0.10 inch).
ACCESS TO SHIM PACKS

Models with 3/4-lnch Nut
Jack up the frame to raise the wheel off the ground.
This will allow the proper upper control arm to drop down
far enough to use a socket on the nuts and permit shim
adjustment. Torque to specifications, refer to FRONT
SUSPENSION AND AXLE (SEC. 3C).
Models with 7/s-lnch Nut

Remove the upper control arm bumper; then follow the
s a m e p ro c e d u re as w ith 3/4 -in ch N u t. T orque to
specifications. Reinstall the upper control arm bumper
w h e n a lig n m e n t is c o m p le te d . R e fe r to F R O N T
SUSPENSION AND AXLE (SEC. 3C).
CASTER
All caster specifications are given with a frame angle of
zero. Therefore, it will be necessary to know the angle of
the frame (whether up in rear or down in rear) before
a corrected caster reading can be determined. Camber
and toe-in can be read as is from the alignm ent
equipment.
How To Determine Caster (Figure 2 and 3)

All caster specifications are given with vehicle frame
angle of zero.
1. Position the vehicle on a smooth level surface.
2. Use a bubble protractor or inclinometer to measure the
frame angle. Frame angle is the degree of tilt in the
frame from the level position.
3. Determine whether the frame angle is up in rear or
down in rear.
4. Determine the caster angle reading from the alignment
equipment.
5. Refer to figure 3. To determine an actual (corrected)
caster reading with various frame angles and caster
readings, one of the following rules apply:
A.
B. C a m b e r
C. A d d s h im s here to in cre a se c a s te r
E. S u b tra c t s h im s here to in c re a s e c a s te r
F. A d d s h im s e q u a lly to in c re a s e c a m b e r
B-07372
Figure 3Caster-Camber Adjustment

a. A DOWN IN REAR frame angle must be
SUBTRACTED from a POSITIVE caster reading.
b. An UP IN REAR frame angle must be
ADDED to a POSITIVE caster reading.
c. A DOWN IN REAR frame angle must be
ADDED to a NEGATIVE caster reading.
d. An UP IN REAR fram e angle m ust be
SUBTRACTED from a NEGATIVE c a s te r
reading.
6. Dimension BC measured 90 degrees from the lower
surface of the crossmember (C) and to the inboard rear
corner of the jounce bumper bracket (B).
7. Using dimension BC and the caster, camber, wheel
toe-in chart sheet, find the recommended caster angle.
8. If the actual (corrected) caster cycle (Step 5) is not
within the recommended caster angle (Step 7) make
the necessary shim changes.
CAMBER
1. Determine the camber angle from the alignm ent
equipment.
2. Add or subtract shims from both the front and rear
bolts to affect a change.
TOE-IN
1. Determine the toe-in from the alignment equipment.
2. Change the length of both tie rod sleeves to affect a toe
change. Toe-in can be increased or decreased by
changing the length of the tie rod ends. A threaded
sleeve is provided for this purpose. When the tie rod
ends are mounted ahead of the steering knuckle they
must be decreased in length in order to increase
toe-in. When the tie rod ends are mounted behind the
steering kunckle they must be lenghtened in order to
increase toe-in. Refer to STEERING LINKAGE (SEC.
3B1) for clamping instructions.
3.4
3 .1
3.2
3.0
2.00
3.0
2.7
3 .0
2.5
57.2
2.25
2.9
2.4
2 .6
63.5
2.50
3.7
1.5
2.7
2.1
70
2.75
3.5
1.2
2.5
76.2
3.00
3.2
0.9
2.3
38.1
1.50
44.5
1.75
50.8
3.25
2.9
88.9
3.50
2.6
95.3
3.75
2.4
P300
P300 (32)
w/JB8 or JB9 W/JB8 or JB9
Except FS3
Except FS3
P30/3500
(32,42)
W/FS3
V100 + 200
+ 300 (00)
+ 5
+ 8
3.2
NOMINAL
NOMINAL
2.2
2.9
(References
(References
2.3
1.9
2.6
5.5
only.no
only, no
1.8
2.0
1.6
2.4
5.3
means of
means of
1.5
1.7
1.3
2.1
5.0
adjustment
adjustment
o
CO
o
82.5
R200 + 300
(00)
2.2
1.2
1.4
1.1
1.8
4.7
0.3
2.0
1.0
1.2
0.8
1.5
4 .4
0.1
1.8
o
^1
o
R100
(00)
P200 + 300
(42) W/R05
Except FS3,
JB8 or JB9
0.9
0.5
1.2
4.1
1.8
114.3
4.50
120.7
0.3
1.0
-0.15
1.5
0.2
0.4
0.7
3.5
1.5
-0.7
1.4
-0.03
0.2
-0.2
0.5
3.3
4.75
1.3
-1.0
-0.1
0.2
3.1
127
5.00
1.0
-1.2
-0.1
2.9
133.4
5.25
-1.4
-0.3
2.6
139.7
5.50
0.5
-1.6
-0.5
2.4
146
5.75
0.3
-1.8
-0.7
2.2
152.4
6.00
2.0
0.6
CO
oo
o
4.25
0.5
o
bo
o
o
o
108
1.7
2 .1
o
o
o
4.00
101.6
provided).
provided).
(0
g m
a) O
H
m
30
>
>
u
H
z
<0
FRONT END ALIGNMENT
G300
(00)
Dimension
BC
Inches
3A-6
G100 + 200
(00)
P200 + 300
(42) Except
FS3, R05,
JB8 or JB9
Dimension
BC
MM
SPECIFICATIONS (CONTINUED)
CAMBER AND TOE-IN CHART
Model
Camber
Toe Angle
Total Toe-In
R100 (00)
0.70
0.36
4.5 mm (0.18 inch)
R200 + 300 (00)
0.25
+ 1.5
Nominal
(Reference only
no means of
adjustment provided).
0 mm (0 inch)
G100 + 200 (00)
0.50
0.36
4.5 mm (0.18 inch)
G300 (00)
0.25
P200 + 300 (32, 42)

Except FS3
0.25
0.36
4.5 mm (0.18 inch)
+ 1.5
Nominal
(Reference only
no means of
adjustment provided).
0.1
3.0 mm (0.12 inch)
V100 + 200 +300 (00)
P30/3500 (32,42)
with FS3
CASTER, CAMBER, WHEEL TOE-IN

ALIGNMENT SETTING TOLERANCES
Check
Re-Set
Caster
1.00
0.50
Camber
0.75
0.50
Total
Toe-In
3.0 mm (0.12 inch)

0.232
1.5 mm (0.06 inch)

0.116
STEERING LINKAGE 3B1-1
SECTION 3B1
STEERING LINKAGE
manual as indicated at appropriate locations by the term inology: NOTICE: See Notice on page 3B1-1 of this section.
NOTICE: All steering linkage fasteners are im portant attaching parts in that they could affect the perform ance of
vital parts and systems, and/or could result in m ajor repair expense. They must be replaced with one o f the same
part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser
o f all parts.
CONTENTS
SUBJECT
PAGE
Description...................................................................................................................................................................3B1- 1
Diagnosis Of Steering Linkage.................................................................................................................................. 3B1- 2
On-Vehicle S ervice .....................................................................................................................................................3B1- 2
Idler Arm In sp e ctio n ..................................... ..................................................................................................... 3B1- 2
Idler Arm Adjustment (P30(32) M otorhom e)....................................................................................................... 3B1 - 2
Idler Arm Replacement.......................................................................................................................................... 3B1- 3
Relay Rod Replacem ent........................................................................................................................................ 3B1 - 4
Pitman Arm Replacement...................................................................................................................................... 3B1- 5
Steering Shock Absorber Inspection....................................................................................................................3B1- 6
Steering Shock Absorber Replacement................................................................................................................3B1- 7
Tie Rod Replacement (R, G, P20 and 30(42) M o d e ls).......................................................................................3B1- 7
Tie Rod Replacement (V and P30(00)FS3 Models)............................................................................................. 3B1- 8
Connecting Rod Replacement (V and P30(00)FS3 Models)...............................................................................3B1-10
Connecting Rod Replacement (P30(32) Motorhome).........................................................................................3B1-11
S p e c ific a tio n s .............................................................................................................................................................3B1-13
Special T o o ls ...............................................................................................................................................................3B1-14
DESCRIPTION
The steering linkage for the R, G, and P20 + 30(42)
model is composed of a pitman arm, idler arm, relay rod,
two adjustable tie rods and a steering shock absorber (Gmodel). When the steering wheel is turned, the gear ro
tates the pitman arm which forces the relay rod to one
side. The tie rods, which are connected to the relay rod by
ball studs, transfers the steering force to the wheels. The
tie rods are adjustable and are used for toe-in adjust
ments. The relay rod is supported by the pitman arm and
idler arm. The idler arm pivots on a support attached to
the frame rail. On the G-model the steering shock absor
ber is attached to a relay rod and a mounting bracket to
steering gear.
The P30(32) Motorhome model steering linkage has a
sim ilar adjustable tie rod assembly as described above.
When the steering wheel is turned, the gear rotates the
pitman arm which forces the nonadjustable connecting
rod and relay arm to move the relay rod to one side. The
relay arm and idler arm are attached to the frame by sup
port assemblies. The support assemblies are adjustable
for shaft end play. The steering shock absorber is at
tached to the fram e and relay arm (figures 1 through 3).
The V model has a front driving axle assem bly and the
P30(00) with RPO-FS3 has an I-Beam axle assembly. The
steering linkage consists of an adjustable connecting rod,
steering shock absorber, pitman arm and a tie rod which
connects the two steering knuckles together (figures 7
and 8).
The overall condition of the steering linkage affects
steering performance. If parts are bent, damaged, worn or
poorly lubricated, im proper and possibly dangerous
steering action will result.
Whenever any steering linkage components are re
paired or replaced, check the steering geometry and front
end alignment. Refer to FRONT END ALIGNM ENT (SEC.
3A).
3B1-2 STEERING LINKAGE
DIAGNOSIS OF STEERING LINKAGE

Refer to MANUAL STEERING (SEC. 3B2) or POWER STEERING (SEC. 3B3) in this manual, depending on vehicle
equipment.
ON-VEHICLE SERVICE
1. Idler Arm
2. Relay Rod
3. Tie Rod A ssem bly
4. Steering Knuckle
5. Pitman Arm
6 . Steering Gear
B-09657
F igure 1 S tee rin g L inkage R, P20, and P30 (42) M odels
IDLER ARM INSPECTION

In s p e c t (F ig u re s 4 a n d 5)
Raise the vehicle. Allow the front wheels to rotate
freely and the steering mechanism freedom to turn.
Position the wheels in a straight ahead position.
Place a spring scale near the relay rod end of the idler
arm. Exert a 110 N (25 lb.) force upward and then
downward (G model the force is forward and rearward)
while measuring the total distance the arm moves. The
allowable deflection is 3.18mm (1/s inch) for a total of
6.35mm (1/4 inch) (figures 4 and 5). Replace the idler
arm if it fails this test with the exception of the P model
motorhome. Refer to Idler Arm Adjustment (P30(32)
Motorhome), in this section.
Im p o rta n t
Jerking the right wheel and tire assembly back and
forth, causing an up and down movement of the idler
arm, is NOT an acceptable testing procedure. There is
no control on the amount of force being applied to the
idler arm.
Care should be used whenever shimmy complaints are

suspected of being caused by loose idler arms. Before
suspecting suspension or steering components,
technicians should consider areas such as dynamic
imbalance, runout or force variation of wheel and tire
assemblies and road surface irregularities. Refer to
WHEELS AND TIRES (SEC. 3E).
IDLER ARM ADJUSTMENT

(P30(32) MOTORHOME)
The fram e
adjustable for
movement as
idler arm fails
mounted idler support assem bly (10) is

support shaft end play. Check for idler arm
described in Idler Arm Inspection. If the
this test, adjust the support shaft end-play.
A d ju s t (F ig u re 3)
1. Loosen the support assembly jam nut.
2. Tighten the adjuster plug to metal-to-metal contact.
3. Back off the adjuster plug 1/s of a turn (V2 of a flat on
the square nut).
1.
2.
3.
4.
5.
6.
7.
9.
Id le r A rm
Relay Rod
Tie Rod A s s e m b ly
S te e rin g K n u ckle
P itm a n Arm
S te ering Gear
S h o ck A b s o rb e r
Bracket
B-09659
Figure 2Steering Linkage G Model
Tighten
Jam nut to 40 N m (30 ft. lbs.). The adjusting
plug should not rotate.

Tools Required:
J-29193 Steering Linkage Installer (12mm).
IDLER ARM REPLACEMENT

J~| Im portant
Do not attempt to free the ball stud by using a pickle
fork or wedge type tool, because seal or bushing
damage could result (figure 6). Use the proper tool to
separate all ball joints.
E3

Tool Required:
1. Frame bolts to the idler arm.
Tighten
Bolts to Specifications at the end of this
section.
Idler arm frame bolts.

Nut from the idler arm ball stud.
3. Prevailing torque nut to the idler arm ball stud.
Raise the vehicle.
Idler arm (1) from the relay rod (2). Use J-24319-01.
mjH
Position the idler arm (1) on the frame.
2. Relay rod (2) to the idler arm ball stud. Make certain
the seal is on the stud. Tighten tool J-29193 or J-29194
to 54 N m (40 ft. lbs.) to seat the tapers. Remove the
tool.
J-24319-01 Steering Linkage Puller.
L*
NOTICE: For steps 1 and 3 see N o tice on

page 3B1-1 of this section.
Inspect
Tighten
Nut to Specifications at the end of this section.
Ball stud threads for damage.
Lower the vehicle.
Ball stud seal for cuts or other damage.
Clean
Threads on the ball stud and in the ball stud nut.
A djust
Toe-in if necessary. Refer to FRONT END

ALIGNMENT (SEC. 3A) in this manual.
7.
8.
10.
11.
12.
13.
Idler Arm
Relay Rod
Tie Rod Assem bly
Steering Knuckle
Pitman Arm
Steering Gear
Shock Absorber
Connecting Rod
Support Assem blies
Relay Arm
Washer
Grommet
B-09656
Figure 3Steering Linkage P30 (32) Motorhome
RELAY ROD REPLACEMENT
Inspect
Threads on the tie rod and the tie rod end for damage.
Im portant
Use the proper tool to separate all tie rod and ball
joints.
++

Tool Required:
Raise the vehicle.

1. Inner tie rod (3) from the relay rod (2). Refer to Tie
Rod Replacement in this section.
2. Nuts from the idler arm (1) and pitman arm (5) or relay
arm (11) ball studs at the relay rod (2).
3. Relay rod (2) from the idler arm (1). Use J-24319-01.
4. Relay rod (2) from the pitman arm (5) or relay arm (11).
Use J-24319-01.

Ball stud seals for excessive wear.

1. Relay rod (2) to the idler arm (1) and the pitman arm (5)
or relay arm (11) ball stud. Make certain the seal is on
the stud. Tighten J-29193 or J-29194 to 54 N m (40 ft.
lbs.) to seat the tapers. Remove the tool.
NOTICE: See Notice on page 3B1-1 of this

section.
2. Nuts to the idler arm and the pitman arm or relay arm
ball stud.
Nuts to Specifications at the end of this

section.
A. 6.35 m m {AU")
B. A p p ly S p rin g S ca le
3. Inner tie rod (3) to the relay rod. Refer to Tie Rod
Replacement.
B-0737C
Figure 5Checking Idler Arm Movement-G Model
jjjjj*
Lower the vehicle.
PITMAN ARM REPLACEMENT
Clean
Im portant
Threads on the ball stud and the ball stud nut.
Use the proper tool to separate all ball joints.
|+ + | Install or Connect (Figures 1 through 3)

Tools Required:
|*"| Remove or Disconnect (Figures 1, 2, 3, 7 and

8)
Tools Required:

J-29107 Pitman Arm Puller.

J-6632-01 Pitman Arm Remover.
Raise the vehicle.
1. Relay rod nut or connecting rod nut and cotter pin from
the pitman arm ball stud.
2. Relay rod (2) or connecting rod (8) from the pitman arm
(5). Use J-24319-01.
3. Pitman arm nut and washer.
Mark the pitman arm and the pitman shaft. This will
permit proper alignment at assembly.
NOTICE: Donot hammeronpitmanarm, pitman

shaft, or puller. Damage to pitman arm or
steeringgear mayresult.
4. Pitman arm (5). Use J-6632-01 or J-29107.
Inspect
jJ 5 Clean
Threads on the ball stud and ball stud nut.
+4-
Install or Connect (Figures 1, 2, 3, 7 and 8)

Tools Required:
3. Tie Rod A sse m b ly

4. S teering K nuckle
5. Pitm an Arm
6 . S teering Gear
7. S hock A bsorbe r
8 . C on n ectin g Rod A ssem bly

B-07367
Figure 7Steering LinkageP30(00)FS3

NOTICE: For steps 2 and 4 see N otice on
page 3B1-1 o f this section.
STEERING SHOCK ABSORBER

INSPECTION
NOTICE: If a clamp type pitman arm is used,

spread the pitm an arm ju st enough, with a
wedge, to slip the arm onto the pitman shaft
Do n o t spread the p itm an arm m ore than
required to slip over the pitman shaft with hand
pressure. Do not hammer, or damage to the
steering gear may re su lt
Steering shock absorbers are a sealed assembly and

are nonrepairable. Replace the complete assembly if
damaged.
1. Pitman arm (5) on the pitman shaft. Line up the marks

made at removal.
2. Pitman arm washer and nut.
1?
Inspect (Figures 2, 3, 7 and 8)
1. Shock absorber for fluid leakage. A slight film of fluid is

allowable near the shaft seal. If there is excessive fluid
leakage, be sure its from the shock absorber and then
replace the shock absorber.
2. Shock absorber bushing for excessive wear. Replace
the shock absorber if necessary.
Pitman arm nut to Specifications at the end of

this section.
3. Relay rod (2) or connecting rod (8) to the pitman arm
ball stud. Make certain the seal is on the stud. Tighten
tool J-29193 or J-29194 to 54 N m (40 ft. lbs.) to seat
the tapers. Remove the tool.
4. Relay rod nut or the connecting rod castellated nut and
cotter pin to the pitman arm ball stud.
Tighten
Castellated nut to Specifications as instructed
at the end of this section.
Lower the vehicle.
3. Test the shock absorber.

Djsconnect the shock absorber from the frame or
axle end.
Extend and compress the shock absorber using
as much travel as possible. Resistance should
be smooth and constant for each stroking rate.
Replace the shock absorber if any binding or
unusual noises are present.
Install the end of the shock absorber. Torque to
specifications.
A.
3.
4.
5.
7.
8.
Tie Rod A ssem b ly (K30)

Tie Rod A ssem bly
Steering K nuckle
Pitm an Arm
S hock A bsorbe r
C onnectin g Rod A sse m b ly
B-09660
Figure 8Steering LinkageV Models
STEERING SHOCK ABSORBER

REPLACEMENT
Washer (12) and grommet (13) (P30(32) model).

2. Shock absorber mounting nuts and washers.
Tighten
++
1.
2.
3.
I?
Shock absorber mounting nuts and washers.
Washer (12) and grommet (13) (P30(32) model).
Cotter pin and castellated nut.
Shock absorber (7).
Inspect
Shock absorber for leaks and damage.
Shock absorber bushings for wear and damage.
Grommet (13) for wear.
Install or Connect
page 3B1-1 o f this section.
1. Shock absorber with bushings to the axle bracket.
Shock absorber nuts to Specifications at the

end of this section.
3. Castellated nut and cotter pin.
Tighten
TIE ROD REPLACEMENT

(R, G, P20 AND 30(42) MODELS)
There are two tie rod assemblies. Each assem bly is of a
five piece construction, consisting of an adjuster tube, two
clam ps and two tie rod ends. The ends are threaded into
the sleeve and secured with the clamps. Right and left
hand threads are used for toe-in adjustments and steering
gear centering. The tie rod ends should be replaced when
t l Install or Connect (Figures 1 through 3)

Tools Required:
NOTICE: For steps 3 and 5

page3B1-1 of this section.
see
Notice on
If the rod ends were removed, lubricate the tie rod

threads with chassis lubricant.
1. Tie rod ends to the adjuster tube. The number of
threads on both the inner and outer rod ends must be
equal within three threads.
2. Inner tie rod ball studs to the relay rod (2). The seal
must be on the stud. Tighten J-29193 or J-29194 to 54
N-m (40 ft. lbs.) to seat the tapers. Remove the tool.
3. Prevailing torque nut to the inner tie rod ball stud.
excessive up and down motion is present, or when

excessive end play or loss of motion at the ball stud
exists.
Before servicing, note the position of the tie rod
adjuster tube and the direction the bolts are installed. The
tie rod adjuster tube components may be rusted. If the
torque required to remove the nut from bolt exceeds 9
N-m (7 ft. lbs.) d isca rd the nuts and bolts. A p ply
penetrating oil between the clam p and tube and rotate the
clam ps until they move freely. Install all parts, with the
correct part number, in the proper position.
Im portant
Use the proper tool to separate all tie rod and ball
joints.
Remove or Disconnect (Figures 1, 2, 3, and 9)

Tool Required:
J-6627-A Wheel Stud Remover and Tie Rod
Remover.
Raise the vehicle.
1. Cotter pins and castellated nuts from the outer tie rod
ball stud.
2. Outer tie rod ball studs from the steering knuckle (4).
Use J-6627-A (figure 9).
3. Inner tie rod ball stud from the relay rod (2). Use
J-6627-A.
4. Tie rod ends from the adjuster tube. Loosen the clamp
bolts and unscrew the end assemblies.
L*
Inspect
Nut to Specifications at the end of this section.

4. Outer tie rod ball studs to the steering knuckle.
5. Castellated nuts and cotter pins to the outer rod ball
studs.
C a s te lla te d n uts to S p e c ific a tio n s

instructed at the end of this section.
as
Adjust (Figures 10, 11, and 12)

Toe-in. Refer to FRONT END ALIGNMENT (SEC.
3A) in this manual.
6. Adjuster tube clamp bolts (figures 10, 11 and 12).
Before tightening the clamp bolts, be sure the following
conditions have been met:
The clamp must be positioned between the
locating dimples at either end of the adjuster
tube.
The clam ps must be positioned w ithin the
angular travel shown in figures 10, 11 or 12.
Both inner and outer tie rod ends must rotate for
their full travel. The position of each tie rod end
must be maintained as the clamps are tightened
to ensure free movement of each joint.
The clamp ends may touch when nuts are
torqued to specification, but the gap next to the
adjuster tube m ust NOT be less than the
minimum dimension shown in figures 10, 11 or
12.
Tighten
Adjuster tube clamp bolts to Specifications at
the end of this section.
Tie rod end for damage.

Tie rod end seals for excessive wear.
Threads on the tie rod and tie rod end for damage.
TIE ROD REPLACEMENT

(V AND P30(00)FS3 MODELS)
Adjuster tube for bending or damaged threads.
gi

Clean
The tapered surfaces.
Tool Required:
J-6627-A Wheel Stud Remover and Tie Rod
Remover.
VIEW A
4.
C.
D.
E.
F.
G.
S te e rin g K n u c k le
C la m p s M u st Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts
A d ju s te r Tube S lo t
S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p Jaw s.
R earw ard R o ta tio n
C la m p E nds M ay T ouch W h e n N u ts A re T orqued To S p e c ific a tio n s .
B u t T he Gap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005 Inch).
B-07290
Figure 10Tie Rod Clamp and Adjuster Tube Positioning R Model
4FRT
VIEW A
4. S te e rin g K n u c k le
i
C. C la m p M u s t Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts
D. S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p J a w s
E. R earw ard R o ta tio n
F. A d ju s te r Tube S lo t
G. C la m p Ends M ay T ouch W h e n N u ts A re T orqued To S p e c ific a tio n s .
B u t T he G ap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005-inch).
____________________________________________________________________________________________________________ B-07291
Figure 11Tie Rod Clamp and Adjuster Tube Positioning G Model
VIEW A
C. C la m p s M u s t Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts
D. A d ju s te r Tube S lo t
E. S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p Ja w s.
F. R earw ard R o ta tio n
G. C la m p E nds M ay Touch W h e n N u ts Are T orqued To S p e c ific a tio n s .
B u t T he G ap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005 Inch).
B-07292
Figure 12Tie Rod Clamp and Adjuster Tube Positioning All Models, Excluding FS3

1. Cotter pins and castellated nuts from the rod assembly
(3).
2. Shock absorber (7) from the tie rod assembly (3).
3. The rod ball studs from the steering knuckle (4). Use
J-6627-A.
4. Tie rod end bodies. Count the number of turns needed
to remove the tie rod end bodies.
5. Tie rod ends from the adjuster tube. On V30 models,
note the position of the adjuster tube, and the direction
from which the bolts are installed.
L*
Inspect

Tool Required:
Raise the vehicle.
1. Castellated nuts and cotter pins from the connecting
rod (8).
2. Connecting rod (8) from the pitman arm (5). Use
J-24319-01.
3. Connecting rod (8) from the steering knuckle (4). Use
J-24319-01.
Im portant
Tie rod for bending or damaged threads.

Tie rod end seals for wear.
Adjuster tube for bending or damaged threads (V30).
4. Connecting rod ends from the adjuster tube. Loosen

the clamp bolts and unscrew the end assemblies.
The connecting rod adjuster tube components
may be rusted. If the torque required to remove
the nut from the bolt exceeds 9 N m (7 ft. lbs.)
discard the nuts and bolts.
The tapered surfaces.

i l Install or Connect (Figures 7 and 8)

If the tie rod ends were removed, lubricate the tie rod
threads with chassis lubricant.
1. Tie rod end bodies to the tie rod (if removed). Screw
the rod assembly on the same number of turns as
when removed.
Tie rod ends to the adjuster tube (V30).
2. Outer tie rod ball studs to the steering knuckle (4).
3. Shock absorber (7) to the tie rod assembly.
NOTICE: See Notice on page 3B1-1 of this

section.
Apply penetrating oil between the clamps and

the tube. Rotate the clamps until they move
freely.
I?
Inspect

Ball stud seals for wear.
Adjuster tube for bending or damaged threads.
Clean
4. C astellated nuts and cotter pins to the tie rod

assembly.
Tighten
Before removing the connecting rod adjuster

tube, note the position of the tube and the
direction from which the bolts are installed.
as
Install or Connect (Figures 7, 8, 13, and 14)

page3B1-1of this section.
see
Notice on
Adjust
If the connecting rod ends were removed, lubricate the

connecting rod threads with chassis lubrication.
Toe-in. Refer to FRONT END ALIGNMENT (SEC.

3A) in this manual.
1. Connecting rod ends to the adjuster tube. The number

of threads on both the inner and outer connecting rod
ends must be equal within three threads.
Tighten
Jam n ut at th e tie rod end b o d ie s to
Specifications at the end of this section.
Adjuster tube clamp bolts to Specifications at
the end of this section (V30).
2. Inner connecting rod (8) ball stud to the pitman arm (5)
(on V models install the short end). Make certain the
seal is on the stud.
3. Castellated nut and cotter pin to the inner connecting
rod ball stud.
Tighten
CONNECTING ROD
REPLACEMENT
(V AND P30(00)FS3 MODEL)
The adjustable connecting rod is used for centering the
steering gear with the front axle. Replace the connecting
rod if the rod is bent or if the ball stud is loose.
Im portant
Use the proper tool to separate all ball joints.

4. Outer connecting rod ball stud to the steering knuckle
(4).
5. Castellated nut and cotter pin to the outer connecting
rod ball stud.
Tighten

The connecting rod ends to the pitman arm and
steering knuckle must be in correct relationship to
each other after adjustment within 2 degrees (V
model).
Adjust
Steering gear high point centering. Refer to
POWER STEERING (SEC. 3B3) in this manual.
6. Adjuster tube clamp bolts (figures 13 and 14). Before
tightening the clamp bolts, be sure the following
conditions have been met.
The clamps must be positioned between the
locating dimples at either end of the adjuster
tube.
The clam ps must be positioned w ithin the
angular travel shown in figures 13 and 14.
The clamp ends may touch when nuts are
torqued to specification, but the gap adjacent to
adjuster tube must NOT be less than minimum
dimension shown in figures 13 and 14.
Both inner and outer connecting rod ends must
rotate for their full travel. The position of each
connecting rod end must be maintained as the
clamps are tightened to ensure free movement of
each joint.
Tighten
Adjuster tube bolts to Specifications at the end
of this section.
Lower the vehicle.
CONNECTING ROD
REPLACEMENT
(P30(32) MOTORHOME)
The non-adjustable connecting rod is used to connect
the pitman arm to the relay arm. Replace the connecting
rod if the rod is bent or the ball stud is loose.
| 2 | Important
Use the proper tool to separate the ball joints.
|<--| Remove or Disconnect (Figure 3)

Tool Required:
Raise the vehicle.
1. Castellated nuts and cotter pins from the connecting
rod (8).
2. Connecting rod (8) from the pitman arm (5). Use
J-24319-01.
C. C la m p s m u s t be b e tw e e n and c le a r o f
d im p le s b e fo re to rq u in g n u ts.
D. O u tb o a rd R o ta tio n
E. A d ju s te r Tube S lo t
F. S lo t in a d ju s te r tu b e m u s t n o t be w ith in
th is area o f c la m p ja w s.
G. C la m p e n d s m ay to u c h w h e n n u ts
are to rq u e d to s p e c ific a tio n s . B u t th e gap
n e x t to th e a d ju s te r tu b e m u s t be v is ib le .
M in im u m gap is 0.127 m m (0.005-inch).
3. Connecting rod (8) from the relay arm (11). Use

J-24319-01.
I*
Inspect

jjQ| Clean
B-07293
Figure 13Connecting Rod Clamp and Adjuster

Tube PositioningP30(00)FS3
C. S lo t O f A d ju s te r Tube M ay Be In A n y P o s itio n On A rc S h o w n B u t N o t C lo s e r T han 2.54 m m (0.10

Inch) To T he E dge O f C la m p Ja w s O r B e tw een.
Figure 14Connecting Rod Clamp and Adjuster Tube Positioning V Model

1. Connecting rod (8) to the pitman arm (5) and relay arm
( 11).
2. Castellated nuts and cotter pins.
Tighten
Lower the vehicle.
as
Tie Rod (3) End To Steering Knuckle (4)*
P20 AND 30(42)
G Model
R Model
P30(00)FS3
P30(32) Motorhome
V Model
N-m
Ft. Lbs.
N-m
Ft. Lbs.
N-m
Ft. Lbs.
N-m
Ft. Lbs.
N-m
Ft. Lbs.
N-m
Ft. Lbs.
62
46
62
46
62
46
62
46
220
162
55
40
Tie Rod (3) Adjuster Tube Bolts
19
14
19
14
19
14
19
14
55
40
Tie Rod (3) To Relay Rod (2)
90
66
90
66
90
66
90
66
Idler Arm (1) To Relay Rod (2)
90
66
90
66
90
66
90
66
Idler Arm (1) To Frame
40
30
47
35
40
30
Pitman Arm (5) To Relay Rod (2)
90
66
90
66
90
66
Pitman Arm (5) To Steering Gear (6)
250
184
250
184
250
184
Bolt To Shock Absorber Bracket (9)
89
66
Shock Absorber (7) To Tie Rod (3)*
62
46
62
46
62
46
Shock Absorber (7) To Frame
62
46
11
47
35
110
81
Shock Asborber (7) To Idler Arm (1)*
62
46
Connecting Rod (8) To Adjuster Tube Bolts
68
50
54
40
Tl
Connecting Rod (8) To Pitman Arm (5)*
95
70
95
70
120
89
Connecting Rod (8) To Steering Knuckle (4)*
95
70
120
89
>
Connecting Rod (8) To Relay Arm (11)*
95
70
Support Assemblies (10) To Frame
65
48
170
125
125
170
125
125
92
Relay Rod (2) To Relay Arm (11)
90
66
Tie Rod Jam Nut (V10, 20) & P30(00)FS3
"0
m
o
O
CO
375
277
125
92
LINKAGE
* Tightening Procedure (Castellated Nuts)

1. Tighten to the specified torque.
2. Advance the nut to align the nut slot with the cotter pin hole. Never back the nut off to align the cotter pin hole.
3. Insert a new cotter pin of the correct size.
CO
STEERING
Idler Arm (1) And Relay Arm (11) To

Support Assemblies (10)
170
3B1-13
SPECIAL TOOLS
1.
J-6627-A
2.
J-6632-01
3.
J-29107
4.
J-29193
5.
J-29194
1.
2.
3.
4.
5.
J-24319-01
Tie Rod P uller

Pitm an Arm Puller
Pitm an Arm Puller
Universal Steering Linkage Puller
Steering Linkage In sta lle r (12 mm) GM
Torque Prevailing N uts
6. Steering Linkage In s ta lle r (14 mm) GM
Torque Prevailing N uts
F-02539
Figure 15Special Tools
3B2-1
SECTION 3B2
MANUAL STEERING GEAR

The following notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the term inology NOTICE: See Notice on page 3B2-1 of this Section.
NOTICE: These fasteners are important attaching parts in that they could affect the perform ance of vital components and
systems, and/or could result in major repair expense. They must be replaced with one of the same part num ber or with an
equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design.
Torque values must be used as specified during reassembly to assure proper retention of these parts.
CONTENTS
SUBJECT
PAGE
Description...................................................................................................................................................................3B2Diagnosis Of Manual Steering S y s te m ....................................................................................................................3B2On-Vehicle S e rvice .....................................................................................................................................................3B2Maintenance.............................................................................................................................................................3B2Steering Gear Replacem ent.................................................................................................................................. 3B2Pitman Shaft Seal Replacement............................................................................................................................3B2Steering Gear Adjustments............... ..................................................................................................................3B2Steering Gear High Point Centering......................................................................................................................3B2S pe cifica tio ns.............................................................................................................................................................3B2Special T o o ls ...............................................................................................................................................................3B2-
1
2
3
3
3
5
5
7
7
8
DESCRIPTION
The steering gear is the recirculating ball nut and worm
type. The worm is located on the lower end of the steering
shaft. The ball nut is mounted on the worm and the steel
balls act as a rolling thread between the worm and nut to
provide a low friction drive between them.
Teeth on the ball nut engage teeth on the pitman shaft
sector. The teeth on the ball nut are made so that a tighter
fit exists between the ball nut and pitman shaft sector
teeth when the front wheels are in the straight ahead posi
tion. The sector teeth are slightly tapered so that a proper
preload may be obtained by moving the pitman shaft end
ways by means of a preload adjuster screw which extends
through the gear housing side cover. The head of the pre
load adjuster and a selectively fitted shim fit snugly into a
T-slot in the end of the pitman shaft, so that the screw also
controls the end play of the shaft (figure 1).
3B2-2 MANUAL STEERING GEAR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Fram e B o lt
S p a ce r
A d ju s te r S cre w
Ja m N u t
P in ch B o lt
F le x ib le C o u p lin g
N ut
S te e rin g S h a ft
W orm S h a ft
P itm a n A rm
P itm a n A rm N u t
A d ju s te r N u t
A d ju s te r P lug
B-07689
Figure 1Steering Gear - R Models
DIAGNOSIS OF MANUAL STEERING SYSTEM

PROBLEM
Rattle Or Chuckle In
The Steering Gear
Poor Return Of The

Steering Wheel
POSSIBLE CAUSE
1. Insufficient or improper lubricant in the
steering gear.
2. Pitman arm loose on the shaft or the
steering gear m ounting bolts loose.
3. Loose or worn steering shaft bearing.
4. E xcessive o ver-ce nter lash or worm
thrust bearings adjusted too loose. On
turns a slight rattle may occur, due to the
increased lash between ball nut and pit
man shaft as gear moves off the center
of high point position. This is normal
and lash must not be reduced to elim i
nate this slight rattle.
1. Steering column misaligned.
steering gear or front suspension.
3. Steering gear adjusted too tight.
4. Front wheel alignm ent incorrect (Caster).
Excessive Play Or
Looseness In The
Steering System
1. Front wheel bearings loosely adjusted.

2. Steering system out of alignment.
3. Worn upper ball joints.
CORRECTION
1. Add specified lube.
2. Tighten to specified torque.
3. Replace steering shaft bearing.
4. Adjust steering gear to specified pre
loads.
1. Align the column.

2. Lubricate as specified.
3. Adjust over-center and thrust bearing
preload to specifications.
4. Adjust to specifications.
1. Adjust bearings or replace with new
parts as necessary.
2. Align caster, camber, and toe-in.
3. Check and replace ball joints if neces
sary.
MANUAL STEERING GEAR 3B2-3
DIAGNOSIS OF MANUAL STEERING SYSTEM (CONT.)

POSSIBLE CAUSE
CORRECTION
4. Steering wheel loose on the shaft, loose

pitman arm, tie rods, steering arms or
steering linkage ball nuts.
5. Tires badly worn, edge of tires rounded
off.
6. Excessive over-center lash.
4. Tighten to specification, replace if worn

or damage.
PROBLEM
Excessive Play Or
Looseness In The
Steering System
(Cont.)
7. Worm thrust bearings loosely adjusted.
Hard Steering
Excessive Effort
Required At The
Steering Wheel
1. Low or uneven tire pressure.

steering gear or front suspension.
3. Steering shaft fle xib le co up lin g m is
aligned.
5. Front wheel alignm ent incorrect.
5. Install new tires, and check alignm ent.

6. Adjust over-center preload to specifica
tions.
7. Adjust the worm thrust bearing preioad
to specifications.
1. Inflate to specified pressures.
2. Lubricate as specified. Relubricate at
specified intervals.
3. Align the column and couplings.
5. Check the alignm ent and correct as
necessary.
ON-VEHICLE SERVICE
MAINTENANCE
The steering gear is factory-filled with steering gear
lubricant. Seasonal change of the lubricant should not be
performed and the housing should not be drained. No
additional lubrication is required for the life of the steering
gear.
A t in te r v a ls s p e c ifie d in M A IN T E N A N C E A N D
LUBRICATION (SEC. OB) of this manual, the gear should
be inspected for seal leakage (actual solid grease not
ju s t oily film ). If a seal is replaced or the gear is
overhauled, the gear housing should be refilled with
S tee rin g G ear L u b rica n t m eeting GM sp e c ific a tio n
1051052 (or equivalent).
NOTICE: DO NOT USE EP Chassis Lube to
lubricate the gear. DO NOT OVER-FILL the gear
housing, or damage may occur.
2. Lower universal joint pinch bolt (6) (G-Models). Mark

the relationship of the clamp (20) to the worm shaft
(11).
Mark the relationship of the pitman arm (12) to the

pitman shaft (21).
3. Pitman shaft nut (13) and washer (14).
4. Pitman arm (12) from the pitman shaft (21). Use
J-6632-01 or J-29107 (figure 3).
5. Frame bolts (1) and washers (2).
6. Pinch bolt (6) and coupling (7) from the worm shaft
(11) (C-Models).
7. Gear assembly.

NOTICE: See N o tice on page 3B2-1 o f this
section for steps 3, 5 and 8.
C-Models
STEERING GEAR
REPLACEMENT
Remove or Disconnect (Figure 1, 2 and 3)
Tools R equired:
J-6632-01 Pitman Arm Remover
J-29107 Pitman Arm Puller
Place the front wheels in a straight ahead position.
1. F le x ib le c o u p lin g to s te e rin g s h a ft n u ts (9)
(R-Models).
1. F le x ib le c o u p lin g (7) o n to th e s te e rin g g e a r

wormshaft (11).
Align the flat in the coupling with the flat on
the shaft.
Push the coupling onto the shaft until the
w o rm s h a ft b o tto m s on th e c o u p lin g
reinforcement.
2. Pinch bolt (6) and torque to 41 N m (30 ft. lbs.). The
bolt must pass through the shaft undercut.
Place the steering gear in position, guiding the
coupling bolt into the shaft flange.
3. Steering gear to frame bolts (1) and torque to 100
N m (75 ft. lbs.).

1.
2.
4.
5.
6.
11.
12.
Fram e B o lt
W a sh er
A d ju s te r S cre w
Jam N ut
P in ch B o lt
W orm S h a ft
P itm a n A rm
13.
14.
15.
20.
21.
P itm a n A rm N ut
S p rin g W a sh er
A d ju s te r N ut
L ow er C la m p
P itm a n S h a ft
B-07688
Figure 2Steering Gear - G Models

Im portant
If fle x ib le c o u p lin g a lig n m e n t pin p la s tic
s p a ce rs w ere used, m ake su re th e y are
bottom ed on the pins.
If fle x ib le c o u p lin g a lig n m e n t pin p la s tic
spacers w ere not used, ce nte r the pins in
the slots in the ste ee rin g sh aft flange.
4. Washer (8) and nut (9) onto the coupling bolts.
Tighten
N ut to 24 N m (18 ft. lbs.).
G-Models
Place the steering gear in position, guiding the
worm shaft into the universal joint assembly and
lining up the marks made at removal. If a new gear
was installed, line up the mark on the wormshaft
with the slit in the universal joint yoke.
5. Steering gear to frame bolts (1).
4. A d ju s te r S crew
5.
11.
15.
16.
Jam N ut
W orm S h a ft
A d ju s te r N ut
A d ju s te r Plug
21.
25.
26.
27.
3. Pitm an sh aft seal from the gear housing using a

s c re w d riv e r. Be c a re fu l n o t to d a m a g e th e
housing bore.
P itm a n S h a ft
S ide C over B o lt
S id e C over
W o rm s h a ft Flat
4. Jam nut (5).

5. Side cover (26) from the pitm an sh aft assem bly.
Turn the adjuster screw (4) clockw ise.
B-07707
Figure 4Steering Gear Assembly

Tighten
6. Universal joint pinch bolt. The pinch bolt must pass
through the shaft undercut. Torque to 60 N-m (44 ft.
lbs.).
ALL MODELS
7. Pitman arm (12) onto the pitman shaft. Line up the
marks made at removal.
8. Washer (14) and nut (13).
Tighten
N ut to 250 N-m (185 ft. lbs.)
PITMAN SHAFT SEAL

REPLACEMENT
The pitm an sh aft seal m ay be replaced w ith o u t
removing the steering gear. Remove the pitman arm as
outlined under Steering Gear R eplacem ent or refer to
STEERING LINKAGE (SEC. 3B1).

R otate th e ste e rin g w heel from stop to stop,
co un ting the total n um ber o f turns. Then turn
back exactly halfway, pla cing the g ear on center
(the w o rm sh a ft fla t (27) sh ou ld be at th e 12
oclo ck position).
1. Side cover bolts (25).
2. Pitm an sh aft (21) and side cover (26) a ssem bly
from the housing.
L*
Inspect
G ear
lu b r ic a n t
fo r
c o n t a m in a t io n .
If
conta m in ated , th e gear m ust be rem oved and
overhauled.
-- Install or Connect (Figure 4 and 5)

Lubricate the new pitm an sh aft seal w ith steering
gear lubricant.
1. Pitm an sh aft seal. Position the seal in the pitm an
sh aft bore and tap into position using a 25 mm (1
inch) pipe or socket (figure 5).
Place the p itm an sh aft (21) in the steering g ear so
th at the ce nte r tooth o f the pitm an sh aft sector
enters the ce nte r tooth space of the ball nut.
Fill the steering g ear housing w ith S teering G ear
L ub rica nt m eeting GM S pecification 1051052 (or
equivalent).
2. New gasket onto the g ear housing.
3. Side cover (26) onto the adjuster screw (4). Reach
through the threaded hole in the side cover w ith a
sm all screw driver and tu rn the adjuster screw
c o u n terclockw ise until it bottom s and tu rn s back
in 1/4 turn.
4. Side cover bolts (25) and torque to sp ecifications.
5. Jam nut (5).
A djust
S teering g ear as outlined under S teering
G ear A d ju s tm e n ts .
6. Pitman arm.

A djust (Figure 4)
T hru st bearing preload as follows:
1. Tighten the adjuster plug (16) until the proper
loading preload is 0.6-1 N m (5-8 in. lbs.).
NOTICE: See N otice on page 3B2-1 of this
section.
2. Tighten the adjuster nut (15) to 115 N m (85 ft.
lbs.).
3. If the gear feels lum py after adjustment,
there is probably damage in the bearings due
to severe impact or improper adjustm ent; the
gear must be disassembled for replacement of
damaged parts.
Over-center preload as follows:
1. Turn the steering wheel gently from one stop
STEERING GEAR
ADJUSTMENTS
Before any adjustments are made to the steering gear,
in an attempt to correct such conditions as shimmy, loose
or hard steering etc., a careful inspection should be made
of the front end alignm ent, shock absorbers, wheel
balance and tire pressure for the possible steering system
problem.
C o rre ct a d ju s tm e n t of th e s te e rin g g e a r is very
important. Perform adjustments following the sequence
listed below.
|+ + | Remove or Disconnect (Figures 1, 2, 3 and 4)
1.
2.
3.
4.
Tools R equired:
J-6632-01 Pitman Arm Remover
J-29107 Pitman Arm Puller
Raise the vehicle.
Pitman arm nut (13) and washer (14).
Mark the relationship of the pitman arm to the
pitman shaft.
Pitman arm using J-6632-01 or J-5504-D (figure 2).
Loosen the adjuster nut (15) and then back the
adjuster plug (16) off 1/4 turn.
Horn cap or cover.
Turn the steering wheel gently in one direction until
stopped by the gear; then turn back one-half turn.
NOTICE: Do not turn the steering wheel hard

against the stops when the steering linkage is
disconnected from the gear as damage to the
ball guides could result.
Measure (Figure 6)
Bearing d ra g by app lyin g a torque w rench w ith
the socket on the steering w heel nut and rotate
through a 90 degree arc. Do not use a torque
w rench having a m axim um torque reading of
m ore than 6 N m (50 in. lbs.).
all the way to the other carefully counting the

total number of turns. Turn the wheel back
exactly half-way to the center position.
Turn the over c e n te r a d ju s te r screw (4)
clockwise to take out all lash between the ball
nut and pitman shaft sector teeth and then
tighten the jam nut (5).
Tighten
Jam nut (5) to 30 N m (22 ft. lbs.).
3. Check the torque at the steering wheel, taking

the highest reading as the wheel is turned
th ro u g h
c e n te r
p o s itio n .
R e fe r
to
S pecifications for the proper over-center
preload.
4. If necessary, loosen jam nut (5) and adjust
over center adjuster screw (4) to obtain proper
torque. Tighten the jam nut (5) and recheck
torque reading through center of travel.
Im portant
If m axim um to rq u e is exceeded, turn
o v e r c e n te r a d ju s t e r s c r e w (4 )
c o u n te rc lo c k w is e , th e n com e up on
a d ju stm e n t by tu rn in g the jam nut (5)
in a clockw ise m otion.

1. Pitm an arm (12) onto the p itm an sh aft (21). Line
up the m arks m ade d urin g disassem bly.
NOTICE: See N o tice on page 3B2-1 of this
section.
Tighten
N ut to 250 N m (185 ft. lbs.).
3. Horn cap or cover.
Lower the vehicle to the floor.

STEERING GEAR HIGH
POINT CENTERING
1. Set the front wheels in the straight ahead position.
This can be checked by driving the vehicle a short
distance on a fla t surface.
2. With the front wheels set straight ahead, check the
position of the mark on the wormshaft designating
the steering gear high point. This mark should be at
the top side of the shaft at 12 oclock position and
lined up with the mark in the coupling lower clamp.
3. If the gear has been moved off high point when

setting wheel in straight ahead position, loosen
adjusting sleeve clamp on both left and right hand
tie rods. Then turn both sleeves an equal num ber of
turns in the same direction to bring gear back on
high point.
Im portant
Turning the sleeves an unequal n um ber of
tu rn s or in d ifferent d irections w ill disturb
the toe-in setting of the w heels.
4. A d ju s t to e -in as o u tlin e d in F R O N T EN D
ALIGNMENT (SEC. 3A) (if necessary).
5. Orient sleeves and clam ps when fastening and
to rq u e in g c la m p s to s p e c ific a tio n s . R efer to
STEERJNG LINKAGE (SEC. 3B1).
SPECIFICATIONS
MANUAL STEERING GEAR
M anufacturer...................................................................................................................................... Saginaw Steering Gear
R a tio .................................................................................................................................................................................. 24 to 1
Type.................................................................................................................................................................Recirculating Ball
PRELOAD ADJUSTMENTS
N-m
In. Lbs.
0.6-1.0
5-8
Over Center Sector Preload
0.5-1.2*
4-10*
Total Steering Gear Preload
1.8 Max.
16 Max.
Worm Thrust Bearing Preload
*ln excess of worm bearing preload.
N-m
Ft, Lbs.
Steering Gear to Frame Nuts
100
75
Pitman Shaft Nut
250
185
Side Cover Bolts
45
33
Adjuster Screw Jam Nut
30
22
Adjuster Plug Nut
115
85
SPECIAL TOOLS
3B3-1
SECTION 3B3
POWER STEERING
manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 3B3-1 of the section.
NOTICE: All steering fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser
quality or substitute design. Torque values must be used as specific during reassembly to assure proper retention
of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n .................................................................................................................................................................................... 3 B 3 - 1

In te g ra l Pow er S tee rin g G e a r ............................................................................................................................................. 3 B 3 - 1
H yd ra u lic P u m p s .................................................................................................................................................................... 3 B 3 - 1
D iag no sis O f Pow er S tee rin g S y s te m .................................................................................................................................. 3 B 3 - 5
O il Leak C h e c k .........................................................................................................................................................................3 B 3 - 8
P ow er S tee rin g System T e s t ............................................................................................................................................. 3 B 3 - 8
P ow er S tee rin g S ystem O n -V ehicle S e rv ic e ...................................................................................................................... 3B3-11
M a in te n a n c e ............................................................................................................................................................................. 3 B 3 -1 1
P um p B e lt Tension A d ju s tm e n t.........................................................................................................................................3B3-11
F luid Level A d ju s tm e n t.........................................................................................................................................................3 B 3 -1 2
B le e d in g The P ow er S te e rin g S y s te m ............................................................................................................................. 3 B 3 -1 2
F lu sh in g The P ow er S te e rin g S y s te m ............................................................................................................................. 3 B 3-1 2
S te e rin g Gear H igh P o in t C e n te rin g .................................................................................................................................. 3 B 3-1 3
P o w er S tee rin g Gear R e p la c e m e n t.................................................................................................................................. 3 B 3-1 3
P itm an S h aft Seal R e p la c e m e n t.........................................................................................................................................3 B 3-1 4
S tee rin g Gear A d ju s tm e n ts ..................................................................................................................................................3 B 3 -1 7
P ow er S teering Pum p R e p la c e m e n t................................................................................................................................3 B 3 -1 9
P ow er S teering H o s e s ........................................................................................................................................................... 3 B 3 -1 9
S p e c ific a tio n s ............................................................................................................................................................................. 3 B 3 -3 4
S pecia l T o o ls ............................................................................................................................................................................... 3 B 3 -3 6
DESCRIPTION
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering gear, a pressure hose,
and a return hose (figure 1).
INTEGRAL POWER
STEERING GEAR
The control valve in the steering gear directs the power

steering fluid to either side of the rack piston. The rack
piston converts the hydraulic pressure into a m echanical
force. If the steering system becomes damaged and loses
h y d ra u lic p re ssure, the v e h ic le can be c o n tro lle d
manua"*
HYDRAULIC PUMPS
The power steering gear (figure 2) has a recirculating

ball system which acts as a rolling thread between the
worm shaft and the rack piston. The worm shaft is
supported by a thrust bearing preload and two conical
thrust races at the lower end, and a bearing assembly in
the adjuster plug at the upper end. When the worm shaft
is turned right, the rack piston moves up in gear. Turning
the worm shaft left moves the rack piston down in gear.
The rack piston teeth mesh with the sector, which is part
The hydraulic pump is a vane-type design. There are

two types, submerged and nonsubmerged. Submerged
pump (P models) have a housing and internal parts that
are inside the reservoir and operate submerged in oil: The
n o n s u b m e rg e d p u m p (TC m o d e ls w ith or w ith o u t
reservoir) function the same as the submerged pump
except that the reservoir is separate from the housing and
internal parts (figure 3).
of the pitman shaft. Turning the worm shaft turns the

pitman shaft, which turns the wheels through the steering
linkage.
There are two bore openings at the rear of the pump

housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly, and
3B3-2 POWER STEERING

1. Pitm an Shaft
2. H ousing Ball Plug
3. A d ju ste r Plug
4. Stub S ha ft.
5. Torsion Bar
6. A d ju s te r Plug N ut
7. Return Line
8. Stud B olt O-ring Seals
9. Reservoir
10. Reservoir Cap
11. Reservoir O-ring Seal
12. Pump S haft Seal
13. Pump H ousing
14. Pressure Port Seat
15. Pressure Hose
16. Pressure And Return Port Seat
17. A d ju s tin g Screw Jam Nut
18. End Cover O-ring Seal
19. Side Cover Seal
20. Gear H ousing
Figure 1Power Steering System Typical

end plate. The sm aller opening contains the pressure line
union, flow control valve, and spring. The flow control
orifice is part of the pressure line union. The pressure
relief valve inside the flow control valve limits the pump
pressure (figure 4).
POWER STEERING 3B3-3
LJ
AI
I
D
/ft
L
ft
...
l.
i
E
IT
C. 346.7 m m (13.64 in ch e s) RV M O D E L (T ilt

C olu m n )
D. 72 m m (2.8 in c h e s ) RV M O D E L (S tandard
C o lu m n -C o lu m n S h ift)
E. 353 m m (14 in ch e s) RV M O D E L (S tandard
C o lu m n -F lo o r S h ift)
F. 81.7 m m (3.21 in ch e s) G M O D E L (T ilt C o l
u m n -C o lu m n S h ift)
G. 144.9 m m (5.70 in ch e s) G M O D E L (T ilt C o l
um n-4 Speed)
H. 192 m m (7.5 in ch e s) G M O D E L (S tandard
J. 80 m m (3.1 in c h e s ) G M O D E L (T ilt C o lu m n F lo o r S h ift)
___
iu
J
F-02585
Figure 2Power Steering Gear
TC MODEL
WITHOUT RESERVOIR
WITH RESERVOIR
Figure 3TC and P Pump Models

10
11.
12.
13.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
R e se rvo ir O -R ing Seal

S h a ft Seal
P um p H o u s in g
D ip S tic k
P um p R ing
T h ru s t Plate
Vanes
R e se rvo ir H ole
S p rin g
P ressure R e lie f Valve
F lo w C o n tro l Valve
E xit H ole
O rific e
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
300.
F ilte r
P um p U nio n
S eals
End Plate
R e ta in in g R ing
R o to r
S p rin g
D isch a rg e C a vity
P ressure P late
S tu b S h a ft
F-02580
Figure 4Power Steering Pump
DIAGNOSIS OF POWER STEERING SYSTEM

PROBLEM
Objectionable Hiss
1. Noisy relief valve in the hydraulic pump.
2. Any metal-to-metal contacts through flex

ible coupling.
Rattle Or Chuckle
Noise In Steering
Gear
1. Gear loose on the frame.
2. Steering linkage looseness.

3. Pressure hose touching other parts of
vehicle.
4. Loose pitman arm.
5. Im p ro p e r o ve r-ce n te r a d ju s tm e n t. A
slight rattle may occur on turns because
of in crea se clea ra n ce o ff the high
p o in t. This is normal and clearance
must not be reduced below specified lim
its to eliminate this slight rattle.
Excessive Wheel
Kick-Back Or Loose
Steering
CORRECTION
POSSIBLE CAUSE
1. T here
is som e noise in all p ow er

steering systems. One of the most com
mon is a hissing sound most evident at
standstill parking. Hiss is a high fre
quency noise. The noise is present in
every valve and results from high veloc
ity fluid passing valve orifice edges.
There is no relationship between this
noise and performance of the steering.
Hiss may be expected when steering
wheel is at end of travel or when slowly
turning at standstill.
Do not replace valve unless hiss is
extrem ely objectionable. A rep la ce
ment valve will also exhibit slight noise
and is not always a cure for the objec
tion.
2. Align the steering shaft and gear so the
flexible coupling rotates in a flat plane
and is not distorted as the shaft rotates.
1. Check the gear mounting bolts. Torque
the bolts to specifications.

2. Check linkage pivot points for wear. Re
place if necessary.
3. Adjust the hose position. Do not bend
tubing by hand.
4. Torque the pitman arm bolt.
1. Air in the system.
1. Add oil to the
2. Steering gear mounting loose.
2.
3. Steering linkage joints worn.

4. Front wheel bearings inco rre ctly ad
justed or worn.
5. Steering gear improperly adjusted.
6. Worn or missing poppet valve (steering
gear).
7. Steering gear flexible coupling too loose
on the shaft or the rubber disc mounting
screws loose.
8. Damaged or worn steering gear.
3.
4.
5.
6.
pum p reservoir and

b le ed . C h e ck hose c o n n e c to rs fo r
proper torque.
T ighten a ttaching bolts to specified
torque.
Replace loose parts.
Adjust the bearings or replace with new
parts as necessary.
Adjust to specifications.
Replace the poppet valve.
7. Tighten to specifications.
8. Disassemble and repair the steering

gear as outlined in the unit repair man
ual.
DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

PROBLEM
POSSIBLE CAUSE
Vehicle Leads To One

Side Or The Other
(Keep In Mind The
Road And Wind
Conditions). Test The
Vehicle, Going In
Both Directions, On A
Flat Road.
1. Front end misaligned.

2. Unbalanced steering gear valve. If this is
cause, steering effort will be very light in
direction of lead and heavy in opposite
direction.
3. Steering shaft rubbing the ID of the shaft
tube.
4. Steering linkage not level.
2. Replace the gear valve.
Momentary Increase
In Effort When
Turning The Wheel
Quickly To The Right
Or Left
1. Low oil level in the pump.

2. Pump belt slipping (if used).
3. High internal linkage (steering gear or
pump).
1. Add power steering fluid as required.

2. Tighten or replace belt.
3. Refer to Power Steering System Test
in this section.
Poor Return Of
Steering
1. Tires under-inflated.
2. Lower coupling flange rubbing against
the steering gear adjuster plug.
3. Steering wheel rubbing against direc
tional signal housing.
4. Tight or frozen steering shaft bearings.
5. Steering linkage or ball joints binding.
6. Steering gear to column misalignment.
7. Tie rod pivots not centralized.
1. Inflate to specified pressure.

2. Loosen the pinch bolt and assemble
properly.
3. Adjust the steering jacket.

4. Adjust as required.
4.
5.
6.
7.
8. Lack of lubricant in the suspension ball

joints and the steering linkage.
9. Sticky or plugged valve spool.
10. Rubber spacer binding in the shift tube.
9.
10.
11. Improper front end alignment.

12. Tight steering shaft bearings.
13. Steering gear adjusted too tightly.
11.
12.
13.
14. Kink in return hose.
14.
Steering Wheel
1. Low oil level in pump.
Surges Or Jerks When 2. Loose pump belt.
Turning With Engine
3. Sticky flow control valve.
Running Especially
4. Insufficient pump pressure.
During Parking
5. Faulty gear relief valve.
Hard Steering Effort

In Both Directions
CORRECTION
1. Low tire pressure.

2. Lack of lubricant in suspension or ball
joints.
3. Steering gear to column misalignment.
4. Loose pump belt.
8.
Replace the bearings.

Replace the affected parts.
Align the steering column.
Adjust tie rod ends as required to cen
ter pivots.
Lubricate. R efer to M AIN TEN AN C E
AND LUBRICATION (SEC. OB).
Remove and clean or replace the valve.
Make certain the spacer is properly
seated. Lubricate inside the diameter
with silicone lubricant.
Check and adjust to specifications.
Replace the bearings.
Adjust over-center and thrust bearing
Replace the hose.
1.
2.
3.
4.
Add power steering fluid as required.

Adjust tension to specification.
Replace or clean the control valve.
Refer to Power Steering System Test
in this section.
5. Replace the gear relief valve.
1. Adjust the tire pressure.

2. Lubricate and relubricate at proper in
tervals. Refer to MAINTENANCE AND
LUBRICATION (SEC. OB).
3. Align the steering column.
4. Adjust belt tension to specifications.

PROBLEM
Hard Steering Effort
In Both Directions
(Continued)
POSSIBLE CAUSE
5. Low fluid level in reservoir.
6. High internal leakage (steering gear or
pump).
7. Sticky flow control valve.
8. Lower coupling flange rubbing against
steering gear adjuster plug.
10. Improper front end alignment.
Foaming Milky Power

Steering Fluid, Low
Level And Possible
Low Pressure
Air in the fluid, and loss of fluid due to

internal pump leakage causing overflow.
CORRECTION
5. Fill to proper level. Inspect lines and
joints for external leakage.
6. Refer to Power Steering System Test
in this section.
7. Replace or clean the valve.
8. Loosen the pinch bolt and assemble
properly.
10. Check and adjust to specifications.
Check for leak and correct. Bleed
system. Extremely cold temperatures
will cause system aeriation should the
oil level be low. If oil level is correct and
pump still foams, remove pump from
vehicle and separate reservoir from
housing. Check welsh plug and hous
ing for cracks. If plug is loose or hous
ing is cracked, replace housing.
Low Oil Pressure Due

To Restriction In The
Hose
1. Check for kinks in the hose.

2. Foreign object stuck in the hose.
1. Remove the kinks or replace the hose.

2. Remove the foreign object or replace
the hose.

To Steering Gear.
Refer To Power
Steering System
Test In This Section.
1. Pressure loss in cylinder due to worn pis

ton ring or scored housing bore.
1. Disassemble the steering gear as out

lined in the unit repair manual. Inspect
the ring and housing bore. Replace the
affected parts.
2. Disassemble steering gear and replace
seals.
3. Replace the valve.

To Steering Pump.
Refer To Power
Steering System
Test In This Section.
2. Leakage at the valve rings and valve

body to the worm seal.
3. Leakage at the valve body or a loose fit
ting spool.
4. Damaged poppet valve.
1. Flow control valve stuck or inoperative.
2. Pressure plate not flat against the cam
ring.
3. Extreme wear of cam ring.
4. Scored pressure plate, thrust plate or ro
tor.
5. Vanes sticking in rotor slots.
6. Vanes not installed properly.
7. Air in oil.
8. Low oil level.
9. Loose belt.
10. Damaged hoses or steering gear.
4. Replace the poppet valve.

1. Replace or clean the valve.
2. Replace the pressure plate.
3. Replace and flush the system.
4. Replace parts. (If rotor* replace with ro
tating group), flush the system.
5. Free-up by removing burrs, varnish or
dirt.
6. Install properly. Radius edge to the out
side.
7. Locate source of leak and correct.
Bleed the system.
9. Adjust tension to specifications.
10. Replace as necessary.

PROBLEM
POSSIBLE CAUSE
CORRECTION
Chirp Noise In
Steering Pump
1. Loose belt.
1. Adjust belt tension.
Belt Squeal
(Particularly
Noticeable At Full
Wheel Travel And
Standstill Parking)
1. Loose belt.
1. Adjust belt tension.
Growl Noise In
Steering Pump
1. Excessive back pressure in hoses or

steering gear caused by restriction.
1. Locate restriction and correct. Replace

part if necessary.
Growl Noise In
Steering Pump
(Particularly
Noticeable At
Standstill Parking)
1. Scored pressure plates, thrust plate or

rotor.
2. Extreme wear of cam ring.
1. Replace parts and flush system.

2. Replace parts.
Groan Noise In
Steering Pump
1. Low oil level.

2. Air in the oil. Poor pressure hose con
nection.

2. Torque the connector. Bleed the sys
tem.
Rattle Or Knock Noise

In Steering Pump
1. Loose pump pulley nut.

2. Pump vanes sticking in rotor slots.
1. Torque nut.
2. Free up by removing burrs, varnish or
dirt.
3. Adjust hose position.
3. Pressure hose touching other parts of

vehicle.
Swish Noise In
Steering Pump
1. Faulty flow control valve.
1. Replace part.
Whine Noise In
Steering Pump
1. Pump shaft bearing scored.
1. Replace the housing and shaft. Flush

the system.
OIL LEAK CHECK

1. With the vehicles engine off, wipe the complete
power steering system dry (gear, pump, hoses, and
connections).
2. Check the oil level in the pum ps reservoir and
a d ju s t as d ir e c te d . R e fe r to F lu id L e ve l
Adjustm ent in this section.
3. Start the engine and turn the steering wheel from
stop to stop several times. Do not hold the wheel
against the stops as this may damage the pump.
4. Find the exact areas of leakage and use the
recommended method of repair as shown in figure
5.
POWER STEERING
SYSTEM TEST
The power steering system may be tested using either
J-5176-D, Power Steering Gage, or with J-25323, Power
Steering Analyzer. J-25323 will measure the flow rate in
addition to the pressure (figure 6).
The power steering system test is a method used to
identify and isolate hydraulic circuit difficulties. Prior to
p e rfo rm in g th is te s t th e fo llo w in g in s p e c tio n , and
corrections if necessary, must be made.
&
Inspect
Pump reservoir for proper fluid level.
Pump belt for proper tension.
Tires for correct air pressure.
Power steering system, replacing parts as
necessary.
70
69
60. R ep lace th e d rive s h a ft seal. M ake c e r

ta in th a t th e d rive s h a ft is c le a n and free
o f p ittin g in th e seal area.
61. R ep lace th e re s e rv o ir O -rin g seal.
62. Torque h ose fittin g n u t to 35 N m (25 ft.
lbs.). If leakage p e rs is ts , re p la ce th e Orin g seal.
63. T orque fittin g to 75 N m (55 ft. lbs.). If
lea kag e p e rs is ts , re p la ce th e O -rin g seal.
64. Torque h ose fittin g n u t to 48 N-m (35 ft.
lbs.). If le a k a g e p e rs is ts , re p la c e th e
b ra s s c o n n e c to r a nd re fa c e th e tu b e
fla re . If n u t th re a d s are d a m a g e d , re p la ce
th e n ut.
65. R ep lace th e O -rin g seal.
66. If lea kag e is o b se rve d at (A), fo llo w in g
m a n u fa c tu re rs d ire c tio n s a p p ly L o c tite
75559 so lv e n t and L o c tite 290 adhesive,
o r e q u iv a le n t, to tu b e -h o u s in g c o n n e c
tio n . If leakage is c o m in g fro m (B), re
p la ce th e retu rn tu b e . If c o m in g fro m (C),
re p la ce th e h ose o r clam p.
67. S eat th e p lu g in th e h o u s in g . F o llo w in g
m a n u fa c tu re rs d ire c tio n s a p p ly L o c tite
75559 s o lv e n t and L o c tite 290 adhesive,
o r e q u iv a le n t, to p lu g -h o u s in g area.
68. S eat th e b all in th e h o u s in g w ith a b lu n t
p u n c h . F o llo w in g m a n u fa c tu re rs d ire c
tio n s a p p ly L o c tite 75559 s o lv e n t and
L o c tite 290 adhesive, o r e q u iv a le n t, to
area.
69. C h e c k th e o il level; if lea kag e p e rs is ts
w ith th e level c o rre c t and ca p tig h t, re
p la ce th e cap.
70 If a cra cke d o r b e n t re s e rv o ir is d e te c te d ,
re p la ce th e reservoir.
71. Torque ja m n u t to 48 N-m (35 ft. lbs.). Re

p la ce th e n u t if lea kag e p e rs is ts .
72. Torque s id e c o v e r b o lts to 60 N-m (45 ft.
lbs.). R e p la ce th e s id e c o v e r seal if le a k
age p e rs is ts .
73. Torque h o s e fittin g n u t to 27 N-m (20 ft.
lbs.). If lea kag e p e rs is ts , re p la ce th e Orin g seal.
74. C h e c k fo r se ep ag e b e tw e e n th e to rs io n
b a r and s tu b s h a ft. R ep lace th e ro ta ry
valve a ssem bly.
75. S eat th e b a ll in th e h o u s in g w ith a b lu n t
p u n c h . A p p ly L o c tite 75559 s o lv e n t and
L o c tite 290 adhesive, o r e q u iv a le n t, to
th e b all area.
76. R ep lace th e a d ju s te r p lu g seals.
77. R ep lace b o th p itm a n s h a ft seals.
78. R ep lace end p lu g O -ring seal.
B-07323
Figure 5System Leak Diagnosis
J-5176-D
J-25323
B-07325
Figure 6T oo ls fo r P ow er S tee rin g S ystem Test
Im p o rta n t
All tests are made with the engine idling at normal
operating temperature. Check the idle adjustment
and if necessary adjust the engine idle speed to the
correct specification. Refer to FUEL SYSTEMS
(SEC. 6C).
Test W ith J-5176-D
1. Place a container under the steering gear or pump
to catch the fluid when disconnecting or connecting
the hoses.
2. W ith the engine NOT running, disconnect the
pressure hose at the steering gear or power steering
pump and install J-5176-D to both hoses using
adapter fitting J-5176-20. The gage must be between
the shut-off valve and pump. Open the shut-off
valve.
3. Remove the fi'ler cap from the pump reservoir and
check the fluid level. Fill the pump reservoir, with
power steering fluid, to the full mark on the dipstick.
Start the engine and, m omentarily holding steering
w heel a gainst stop, ch eck the co nn e ctio n s at
J-5176-D for leakage.
4. Bleed the system. Refer to Bleeding the Power
Steering System.
5. Insert therm om eter J-5421-02 in the reservoir filler
opening. Move the steering wheel from stop to stop
several times until the thermometer indicates that
the hydraulic fluid in the reservoir has reached a
temperature of 65 to 77C (150 to 170F).
Im portant
To prevent scrubbing flat spots on the tires, do
not turn the steering wheel more than five
tim es without rolling the vehicle to change the
tire-to-floor contact area.
6. Start the engine and check the pumps fluid level.
Add power steering fluid if required. When the
engine is at normal operating temperature, the initial
pressure read on the gage (valve open) should be in
the 550-860 kPa (80-125 psi) range. Should this
pressure be in excess of 1380 kPa (200 psi)

check the hoses for restrictions and the poppet
valve for proper assembly.
NOTICE: Do not leave valve fully closed for
more than 5 seconds as the pum p could be
damaged internally.
7. Close the gate valve fully 3 times. Record the
highest pressures attained each time.
If the pressures recorded are w ithin the
specifications at the end of this section, and
the range of readings is within 345 kPa (50
p si), th e pum p is fu n c tio n in g w ith in its
specifications.
If the pressures recorded are high, but do not
repeat w ithin 345 kPa (50 psi), the flow
controlling valve is sticking. Remove the valve,
clean it and remove any burrs using crocus
cloth or fine hone. If the system contains some
dirt, flush it. If it is exceptionally dirty, both the
p u m p and g e a r m u s t be c o m p le te ly
d is a s s e m b le d , c le a n e d , flu s h e d and
reassembled before further usage.
If the pressures recorded are constant but
m ore than 690 kPa (100 psi), below the
minimum listed specification, replace the flow
control valve and recheck. If the pressures are
still low, replace the rotating group in the
pump.
8. If the pump checks within specifications, leave the
valve open and turn (or have turned) the steering
w heel into both co rn e rs . R ecord th e h ig h e s t
pressures and compare with the maximum pump
pressure recorded. If this pressure cannot be built in
either (or one) side of the gear, the gear is leaking
internally and must be disassembled and repaired.
9. Shut the engine off, rem ove the testing gage,
reconnect the pressure hose, check the fluid level
and/or make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined. Refer to
Diagnosis of Power Steering System .

Test With J-25323
1. Place a container under the steering gear or pump
to catch the fluid when disconnecting or connecting
the hoses.
2. W ith the engine NOT running, d isco nn ect the
pressure hose at the steering gear or power steering
pump. Thread J-29525 fem ale adapter into the
pressure hose and the male adapter into the gear or
pum p. C onnect J-25323 a nalyzer hoses to the
adapters.
3. If the analyzer has never been used, it will be
necessary to bleed the power steering system to
remove all the air. Refer to Bleeding the Power
Steering System in this section. The analyzer gate
must be open during this procedure.
4. Add power steering fluid to the pump if required.
5. Run the engine at idle speed with the gate valve
open and record flow (A) and pressure (B).
If the flow is below 7.4 L/min. (2 gpm), the
pump appears to be in need of repair, but
continue the test.
If the pressure is above 1035 kPa (150 psi),
check the hoses for restriction and check the
steering gear.
6. Partially close the gate valve to build 4278 kPa (620
psi). Record the flow (C).
If the flow (C) drops more than 3.7 L/min. (1
gpm) under flow (A), disassem ble the pump
and replace the ring, rotor, and vanes. If the
pressure plates are worn or cracked, replace
th e m . R e p la c e a ll O -rin g s e a ls w h e n
reassembling the pump. Continue the test.
7. Com pletely close and partially open the gate valve
three tim es (do not allow the valve to remain
closed for more than 5 seconds). Record the
gate closed pressure (D).
8. Check the pressure specifications, at the end of this
section for the correct pump model, and if the pump
pressure recorded is 690 kPa (100 psi) lower than
the minimum specification listed, replace the flow
9.
10.
11.
12.
control valve in the pump. If the pressure recorded is

above the maximum specification listed, the flow
control valve in the pump should be removed and
cleaned or replaced. If the system is exceptionally
dirty, both the steering gear and pump must be
c o m p le te ly d is a s s e m b le d and c le a n e d b efo re
reassembly.
Increase the engine speed from idle to about 1500
rpm. Record the flow (E).
If flow (E) varies more than 1 gpm from flow
(A), then the flow control valve should be
removed and cleaned or replaced, the same
as in step 8.
Have the steering wheel turned into the left and then
right corner lightly against the wheel stops. Record
the pressure and flow (F).
Pressures developed in both corners should
be nearly the same as the maximum pump
output (D). At the same tim e the flow should
drop below 1.85 L/min. (0.5 gpm).
If the pressure does not reach m axim um
output or the flow does not drop below the
specified value, excessive internal leakage is
o c c u rrin g . R em ove and d isa sse m b le the
steering gear and remove the control valve.
Repair the steering gear as outlined in the
Unit Repair Manual.
Have the steering wheel turned slightly in both
directions and release quickly while watching the
pressure gage. The needle should move from the
normal back pressure reading and snap back as the
wheel is released. If it comes back slowly, or sticks,
the rotary valve in the steering gear is sticking.
Remove, disassem ble and clean the rotary valve. If
the system contains a lot of dirt and foreign material,
d is a s s e m b le th e p u m p th e gear, c le a n and
reassemble.
If the problem still exists, the steering and front
suspension must be thoroughly examined. Refer to
D iagnosis of Power Steering System in this
section.
POWER STEERING SYSTEM ON-VEHICLE SERVICE

MAINTENANCE
The hydraulic system should be kept clean and at
regular intervals the pump steering fluid level in the
reservoir should be checked and flu id added when
required. Refer to MAINTENANCE AND LUBRICATION
(SEC. 0B) of this manual for type of fluid to be used and
intervals for filling.
If the system contains some dirt, flush it as detailed
later in this section. If it is exceptionally dirty, both the
pump and the gear must be completely disassembled
before further usage.
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Inspect the hoses with the wheels in the straight-ahead
position, then turn the wheels fully to the left and right,
while observing the movement of the hoses. Correct any
hose contact with other parts of the vehicle that could

cause chafing or wear.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. The hoses should have sufficient
natural curvature in the routing to absorb movement and
hose shortening during vehicle operation.
A ir in the system will cause spongy action and noisy
operation. When a hose is disconnected or when fluid is
lost, for any reason, the system must be bled after
refilling. Refer to Bleeding the Power Steering System
in this section.
PUMP BELT TENSION

ADJUSTMENT
When adjusting a power steering pump belt, never pry
against the pum p reservoir or pull against the filler neck.
Two systems are used for belt adjustment. On some
models, the pump is loosened from the bracket and

moved outward to lncrea se the tension. On other models,
a half-inch square drive hole is located in the bracket, and
this hole is used to rotate the pump-and-bracket assembly
outward to increase belt tension.
ft
Adjust
Tool Required:
J-23600-B Belt Tension Gage.
1. Place belt tension gage, J-23600-B or equivalent,
midway between the pulleys on drive belts being
checked.
Power steering pump driven by a single belt.
Loosen the pump attaching bolts and adjust
the belt to correct tension by moving the pump
outward, away from the engine.
Tighten finger tight all pump mounting bolts
and remove the pry bar.
Tighten all pum p mounting bolts. Refer to
Power Steering Pump Replacement in this
section.
Inspect belt tension and remove the belt
tension gage.
2. Loosen the pivot bolt and pump brace adjusting
nuts.
NOTICE: Do not move the pum p by prying
against the reservoir or by pulling on the filler
neck, or damage may occur.
3. Move the pump, with the belt in place until the belt
is tensioned to specifications. Refer to ENGINE
COOLING (SEC. 6B1).
4. Tighten the pump bracket adjusting nut and the
pivot bolt nut. Refer to Power Steering Pump
Replacem ent in this section.
5. Inspect the belt tension and remove the belt tension
gage.
FLUID LEVEL ADJUSTMENT

1. Run the engine until the power steering fluid
reaches normal operating temperature, about 80C
(170F), then shut the engine off.
2. Remove the reservoir cap and check the fluid level
on the dipstick. On models equipped with a remote
reservoir, the fluid level should be about 12.7 to 25.4
mm ( 1/2 to 1-inch) from the top when the wheels are
in full left turn position.
3. If the fluid level is low, add power steering fluid (GM
#1050017 or equivalent) to the proper level and
install the reservoir cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
System in this section.
BLEEDING THE POWER

STEERING SYSTEM
W hen a pow er ste e rin g pum p or gear has been
installed, or an oil line has been disconnected, the air that
has entered the system must be bled out before the
vehicle is operated. If air is allowed to remain in the power
steering fluid system, noisy and unsatisfactory operation

of the system may result. Bleed air from the hydraulic
system as follows:
When bleeding the system, and any tim e fluid is
added to the power steering system, be sure to use
o n ly p o w e r s te e rin g flu id as s p e c ifie d in
MAINTENANCE AND LUBRICATION (SEC. OB).
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds.
Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise the front end of the vehicle so that the wheels
are off the ground.
6. Start the engine. Slowly turn the steering wheel
right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle and turn the steering wheel slowly
from lock to lock.
9. Stop the engine. Check the fluid level and refill as
required.
10. If the fluid is extremely foamy, allow the vehicle to
s ta n d a few m in u te s a nd re p e a t th e a bo ve
procedure.
Inspect
Belt for tightness.
Pulley for looseness or damage. The pulley should
not wobble with the engine running.
Hoses so they are not touching any other parts of
the vehicle.
Fluid level and fill to the proper level.
Fluid for air and if present attempt to bleed the
system.
FLUSHING THE POWER

STEERING SYSTEM
1. Raise the front end of the vehicle off the ground
until the wheels are free to turn.
2. Remove the fluid return line at the pum p inlet
connector and plug the connector port on the pump.
Position the line towards a large container to catch
the draining fluid.
3. W hile an assistant is filling the reservoir with new
power steering fluid, run the engine at idle. Turn the
steering wheel from stop to stop. DO NOT contact
wheel stops or hold the wheel in a corner or fluid will
stop and the pump will be in pressure relief mode. A
sudden overflow from the reservoir may develop if
the wheel is held at a stop.
4. Install all the lines, hoses and com ponents (if
removed) on the vehicle. Fill the system with new
power steering flu id and bleed the system as
d e s c rib e d in B le e d in g T he P ow er S te e rin g
System. Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. W hile refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,

d is a s s e m b le and cle a n o r rep la ce th e pow er
steering system components. Do not re-use any
drained power steering fluid.
STEERING GEAR HIGH

POINT CENTERING
1. Set the front wheels in the straight ahead position.
This can be checked by driving the vehicle a short
distance on a flat surface.
2. With the front wheels set straight ahead, check the
position of the mark on the worm shaft designating
steering gear high point. This mark should be at the
top side of the shaft at the 12 oclock position and
lined up with the mark in the coupling lower clamp.
3. On R, G and P models except P30(00)FS3, if the
steering gear has been moved off high point when
setting the wheel in the straight ahead position,
loosen the adjuster tube clam ps on both the left and
right hand tie rods. Then turn both adjuster tubes an
equal number of turns in the same direction to bring
the gear back on high point.
Turning the adjuster tubes an unequal number

of turns or in different directions will disturb
the toe-in setting of the wheels.
4. On V and P30(00)FS3 models, if the gear has been
moved off high point when setting the wheels in the
straight ahead position, loosen the adjuster tube
clam ps on the co n n e ctin g rod. Then tu rn the
adjuster tube to bring the gear back on high point.
5. Adjust toe-in. Refer to FRONT END ALIGNMENT
(SEC. 3A).
6. R efer to STEER IN G LIN KAG E (SEC. 3B1) for
adjuster tube clam ping instructions.
POWER STEERING GEAR

REPLACEMENT
|<-+| Remove or Disconnect (Figures 7, 8, 9, 10, 11,
and 12)
Place a drain pan below the steering gear.
2. Hoses from the steering gear. Raise the hose up to
prevent oil drainage. Cap or tape the ends of the
hose and gear fittings to prevent the entrance of
dirt.
Remove the flexible co up lin g to steering shaft
flange bolts (C, K and P300(32) models).
Remove the lower universal joint pinch bolt. Mark
the relationship of the universal yoke to the stub
shaft (G and P models).
3. Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
4. Steering gear frame bolts and the steering gear.
Tap lightly, using a soft m allet, on the flexible
coupling to remove the coupling from the steering
gear stub shaft (R, V, and P300(32) models).
R, V And P300(32) Models

- Install or Connect (Figures 7, 8 ,1 0 ,1 1 , and 12)
NOTICE: For steps 2, 3 and 4 see N o tic e on
page 3B3-1.
1. Flexible coupling onto the steering gear stub shaft.
Align the flat in the coupling with the flat on
the shaft.
Push the coupling onto the stub shaft until the
coupling reinforcement bottoms against the
end of the shaft.
2. Pinch bolt into the split clamp. The pinch bolt must
pass through the shaft undercut.

Tighten
Pinch bolt to 42 N m (31 ft. lbs.).
Place the steering gear into position, guiding the
coupling bolts into the proper holes in the shaft
flange.
3. S te e rin g g e a r to fra m e b o lts . T o rq u e
to
4. Coupling flange nuts and washers. The coupling

alignm ent pins should be centered in the flange
slots.
Tighten
Coupling flange nuts to 27 N m (20 ft. lbs.).
Maintain a coupling to flange dimension of 6.4
to 9.5 mm (0.250 to 0.375-inch).
3B1).
Remove the plugs and caps from the steering gear
and hoses.
6. Hoses to the steering gear. Torque hose fittings to
G And P Models

Place the steering gear in position. Guide the stub
shaft into the universal joint assembly by lining up
the marks made at removal.
1. S te e rin g g e a r to th e fra m e b o lts . Torque to
2. In te rm e d ia te s h a ft p in c h b o lt. T o rq u e to
Specifications at the end of this section. The
pinch bolt must pass through the shaft undercut.

3B1).
Remove the plugs and caps from the steering gear
and hoses.
4. Hoses to the steering gear. Torque hose fittings to

77 76 75
17.
21.
70.
71.
73.
74.
75.
76.
77.
78.
79.
80.
A d ju s tin g S cre w Jam N u t

S ide C over
M o u n tin g B o lt
S p rin g W a sh er
A d ju s tin g S crew
P in ch B o lt
/
C o u p lin g N u t \ \
S p rin g W a sh er
C o u p lin g F la n g e
C o u p lin g
S ide C ove r B o lt
B-07602
Figure 7Steering Gear InstallationR Model
PITMAN SHAFT SEAL

REPLACEMENT
++
1.
2.
Tools Required:
J-29107 Pitman Arm Puller.
J-4245 Internal Snap Ring Pliers.
Mark the position of the pitman arm to the pitman
shaft. Remove the pitman arm using J-29107. Refer
to STEERING LINKAGE (SEC. 3B1).
Position a drain pan under the steering gear.
Retaining ring using J-4245.
Start the engine and full turn the steering wheel to
the left-turn position for one or two seconds at a
time. This will force the pitman shaft seals and
washers out of the housing.
Stop the engine.
Pitman shaft seals and washers from the pitman
shaft.
17.
21.
70.
73.
74.
75.
76.
77.
78.
79.
Inspect
Pitman shaft seal surfaces for roughness or pitting.
If pitted, replace the shaft.
H ou sing fo r burrs. R em ove th e b urrs b efore
installing the new seals.
jjjjP Clean
Pitman shaft and seal areas using a crocus cloth.
-+ Install or Connect
fo o ls Required:
J-6219 Steering Gear Pitman Shaft Oil Seal
Installer.
J-4245 Internal Snap Ring Pliers.
Lubricate the new seals with power steering fluid.
Apply a single layer of tape to the pitman arm shaft
to avoid damaging the seals.
A d ju s tin g S cre w Jam N ut

S ide C over
A d ju s tin g S cre w
P in ch B o lt
C o u p lin g N u t
C o u p lin g F la n g e
C o u p lin g
80. S ide C ove r B o lt

81. S p a ce r
F-02622
Figure 8Steering Gear InstallationV Model
Figure 9Steering Gear InstallationG Model
17.
21.
70.
71.
73.
74.
75.
76.
77.
78.
79.
80.
81.
A d ju s tin g S cre w Ja m N u t
S id e C ove r
S p rin g W a s h e r
P in ch B o lt
C o u p lin g N u t
C o u p lin g F lan ge
C o u p lin g
S id e C ove r B o lt
Spacer
F-02624
Figure 10Steering Gear InstallationP Model, P300{32) and Solid Front Axle
17.
21.
70.
71.
73.
A d ju s tin g S cre w Jam N ut

S ide C over
M o u n tin g b o lt
S p rin g W a sh er
A d ju s tin g S crew
74.
80.
81.
83.
84.
P in c h B o lt
S id e C over B o lt
S pacer
S p rin g W a sh er
P in ch B o lt N u t
F-02625
Figure 11Steering Gear InstallationP Model, P300(42) + Solid Front Axle
17.
21.
70.
71.
73.
74.
80.
83.
84.
A d ju s tin g S cre w Ja m N u t
S id e C ove r
M o u n tin g b o lt
P in ch B o lt
S id e C o ve r B o lt
P in ch B o lt N u t
F-02626
Figure 12Steering Gear InstallationP Model, P200, P300(42) Except FS3

1 . Single lip seal and washer use J-6219. Install far
enough to provide clearance for the remaining seal,

washer and retaining ring. DO NOT allow the seal to
bottom on the end of the counter bore.
Double lip seal and washer use J-21553.
Retaining ring use J-4245.
Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
STEERING GEAR
ADJUSTMENTS
Before any adjustments are made to the steering
gear, refer to Diagnosis of Power Steering System
for reviewing the possible steering system problems.
The steering gear adjustm e nt is made only as a
correction and not as a periodic adjustment. Adjusting the
steering gear in the vehicle is NOT recommended for two
reasons:
1. The com plexity involved in adjusting the worm
thrust bearing preload.
2. The friction effect provided by the hydraulic fluid in
the steering gear.
For proper adjustment, remove the steering gear from
the vehicle. Drain the power steering fluid from the gear.
M ount the gear in a vise and make the fo llo w in g
adjustments.
The steering gear requires two adjustments which are:
the worm thrust bearing preload and the pitman shaft
over-center preload adjustment.
The worm thrust bearing preload is controlled by the
am ount of compression force exerted on the conical worm
bearing thrust races by the adjuster plug.
The pitman shaft over-center preload is controlled by
the pitman shaft adjuster screw which determines the
clearance between the rack piston and the pitman shaft
sector teeth.
Adjust the worm thrust bearing preload first,

then a djust the pitm an sh aft over-center
preload.
Worm Bearing Preload

^
A djust (Figures 1, 2, 13, 14, 15, 16, and 17)

Tool Required:
J-7624 Adjustable Spanner Wrench.
Loosen and remove the adjuster plug nut (6) (figure
13).
2 . Turn the adjuster plug (3) in (clockwise), using
J-7624, until the plug and thrust bearing are firm ly
bottomed in the housing.
Tighten
Adjuster plug to 27 N m (20 ft. lbs.).
Place an index mark on the housing even with one
of the holes in the adjust plug (figure 14).
4. Measure back (counterclockw ise) 4.7-6.3 mm
(3/ie-1/4-inch) from the index mark and mark the

housing (figure 15).
5. Rotate the adjuster plug back (counterclockwise)

until the hole in the plug is aligned with the second
mark on the housing (figure 16).
6. Install the adjuster plug nut (6).
4. Stub Shaft
21. Side Cover
B-07330
Figure 16Aligning the Adjuster Plug to the

Second Mark
Figure 18Aligning the Stub Shaft

Over Center Preload
Tighten
Nut to 110 N m (81 ft. lbs.). Be sure the
adjuster plug does not turn when tightening
the nut.
7. Use a inch-pound torque wrench and a 12-point
deep socket to measure the required torque to turn
the stub shaft (4). Take the reading with the handle
of the torque wrench near the vertical position. Turn
the stub shaft to the right stop and then back
(counterclockwise) 1/4 turn at an even rate (figure
17). Record the torque reading.
8. The torque required to turn the stub shaft should be
0.45-1.13 N m (4-10 in. lbs.). If the reading is above or
below the specified torque; the adjuster plug may
not be tightened properly or may have turned when
the adjuster plug nut was tightened, or the thrust
bearings and races (22) may be damaged.
Figure 17Checking Rotational Torque
Adjust (Figures 1, 2, 18, 19,, and 20)

1. Turn th e p itm a n s h a ft a d ju s te r s c re w (73)
counterclockw ise until fu lly extended, then turn
back 1/2 turn clockwise.
2. Rotate the stub shaft (4) from stop to stop and count
the number of turns.
3. Smarting at either stop, turn the stub shaft back 1/2
the total number of turns. This is the center of the
gear.
When the gear is centered, the flat on the stub
shaft should face upward and be parallel with
the side cover (21) (figure 14) and the master
spline on the pitman shaft should be in line
with the adjuster screw (73) (figure 19).
4. Place the torque wrench, in the vertical position, on
the stub shaft. Rotate the torque wrench 45 degrees
each side of the center and record the highest drag
torque measured on or near center (figure 20).
Figure 19Aligning the Pitman Shaft Master Spline

4. Pump adjusting bolts, nuts and brackets.
5. Pump assembly.
6. Pulley from the pump.
In s ta ll J-29785-A . Be sure the p ilo t b olt
bottoms in the pump shaft by turning the nut to
the top of the pilot bolt.
H o ld th e p ilo t b o lt and tu rn th e n u t
counterclockwise (figure 28).
-+ Install or Connect (Figures 21, 22, 23, 24, 25,

26, 27, and 28)
1.
2.
5. Adjust over-center drag torque by loosening the

adjuster screw jam nut (17) and turning the pitman
shaft adjuster screw (79) clockwise until the correct
drag torque is obtained.
On new steering gears (under 400 miles), add
0.6-1.2 N m (6-10 in. lbs.) to rq u e to the
previously measured worm bearing preload
torque but do not exceed a total steering gear
preload of 2 N m (18 in. lbs.).
On used steering gears (400 miles or more)
add 0.5-0.6 N-m (4-5 in. lbs.) torque to the
previously measured worm bearing preload
torque but do not exceed a total steering gear
preload of 1.5 N-m (14 in. lbs.).
Tighten
Adjuster screw jam nut (17) to 47 N-m (35 ft.
lbs.).
6. Install the steering gear. Refer to Steering Gear
Installation in this section.
7. Fill the pump reservoir with power steering fluid and
bleed the system. Refer to Bleeding the Power
Steering System in this section.
POWER STEERING PUMP

REPLACEMENT
|<-+| Remove or Disconnect (Figures 21, 22, 23, 24,
25, 26, 27, and 28)
1.
2.
3.
Tool Required:
J-29785-A Water Pump and Power Steering
Pulley Remover.
Place a drain pan below the pump.
Hoses at the pump. Raise the hose up to prevent
drainage of the oil. Cap or tape the ends of the hose
and pump to prevent the entrance of dirt.
On models with remote reservoir, disconnect
the reservoir hose at the pump. Cap the hose
pump fittings.
Loosen the pump adjusting bolts and nuts.
Pump belt.
3.
4.
Tool Required:
J-2 5 0 3 3 -B Pow er S te e rin g P um p P u lle y
Installer.
Brackets to the pump.
Pulley to the pump.
Place pulley on the end of the pump shaft and
in s ta ll J-25033-B . Be sure th e p ilo t b o lt
bottoms in the shaft by turning the nut to the
top of the pilot bolt.
Hold the pilot bolt and turn the nut clockwise
(figure 28).
On models equipped with a remote power steering
pump reservoir fill the pump housing with as much
fluid as possible before mounting.
Pump assembly and attaching parts loosely to the
engine.
Power steering hoses to the pump. Hoses installed
out of position may be subjected to chafing or other
abu ses d u rin g s h a rp tu rn s. R efer to Power
Steering Hoses in this section.
| 9 | Im portant
Do not s ta rt the e ng in e w ith any pow er
steering hose disconnected. After connecting
the power steering hoses make sure there is
clearance between the hoses and the drive
belt, sheet metal or any other components
where hose rub or interference could result.
Fill the reservoir. Bleed the pump by turning the
pulley backwards (counter-clockwise as viewed from
the front) until the air bubbles cease to appear.
5. Pump belt over the pulley.
A djust
Belt tension. Refer to Pump Belt Tension

A djustm ent in this section.
Fill and bleed the system. Refer to Bleeding the
Power Steering System in this section.
POWER STEERING HOSES

When either a hose is reinstalled or replaced, the
following points are essential:
Route hoses in the same position they were in
before removal (figures 29 through 36).
Route hoses smoothly, avoid sharp bends and
kinking.
Tighten the pump end hose fitting, gear line fitting,
and booster line fitting to specifications. Refer to
Figure 21Power Steering Pump MountingRV (4.3, 5.0, and 5.7 Liter)
After hoses are installed, check for leaks while the
system is being bled. Refer to Bleeding the Power
Steering System in this section.
NOTICE: Do not start the engine with any power
steering hose disconnected, or damage to the
components could occur.
RV000(00) With A/C
A. 44 N-m (32 Ft. Lbs.)

B. B a tte ry C a b le (G -M odel)
G200 + 300(00) Without A/C

P000(00) Without A/C
F-02629
Figure 22Power Steering Pump Mounting (6.2 Liter)
P300(00) (7.4 Liter)
P000(42) (4.8 Liter)

F-02631
Figure 23Power Steering Pump Mounting (4.8 and 7.4 Liter)
G000(00) (4.3,5.0 And 5.7 Liter)
C.
D.
E.
F.
84
44
34
25
N m
N m
N-m
N-m
(62
(32
(25
(18
Ft.
Ft.
Ft.
Ft.
Lbs.)
Lbs.)
Lbs.)
Lbs.)
P000(42) (5.7 Liter)

F-02632
Figure 24Power Steering Pump Mounting (4.3, 5.0, and 5.7 Liter)
Figure 25Power Steering Pump MountingG Model (4.3, 5.0, and 5.7 Liter)
F-02596
Figure 26Power Steering Pump MountingRV 000(00)(5.0 and 5.7 Liters) with A/C
B-07363
Figure 28Installing and Removing Pulley
Figure 29Hydro-Boost Lines
Figure 30Power Steering Hoses
Figure 31Power Steering HosesRV (4.3, 5.0, 5.7, and 6.2 Liter)
G300(00) (5.7 Liter)
G000(00) (6.2 Liter)

F-02582
Figure 32-Power Steering HosesG Model (4.3, 5.0, 5.7, and 6.2 Liter)
P000(42) (4.8 Liter)

P300(42) (4.8 Liter)
With Disc/Drum Brake
And 4 Wheel Disc Brake
P300(42) (4.8 Liter)

With 4 Wheel Disc Brake
With Front I Beam Axle
With Warning Switch
P300(42) (4.8 Liter)

With Warning Switch
F-02643
Figure 33Power Steering HosesP Model (4.8 Liter)
P300(42) (5.7 Liter)

With Disc/Drum Brakes
With 4 Wheel Disc Brakes
With Brake Warning Switch
P300(42) (5.7 Liter)

With Front I-Beam Axle
P300(42) (5.7 Liter)

F-02644
P300(32) (7.4 Liter)

P300(42) (7.4 Liter)

F-02645
P300(42) (6.2 Liter)

P300(32) (6.2 Liter)

P300(42) (6.2 Liter)

F-02646
SPECIFICATIONS
STEERING GEAR ADJUSTMENTS
Valve Assem bly And Seal D r a g ...........................................................................................0.1-0.4 N m (1-4 in.
Thrust Bearing Preload (In Excess Of Valve Assem bly And Seal D ra g )....................0.3-0.4 N-m (3-4 in.
Pitman Shaft Over Center Preload
New G e a r ....................................................................................................................... 0.6-1.2 N m (6-10 in.
Used G e a r ....................................................................................................................... 0.4-0.5 N m (4-5 in.
Final Over Center Reading (Total-Maximum)
New G e ar.....................................................................................................................................2 N m (18 in.
Used G e a r................................................................................................................................ 1.6 N m (14 in.
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
Steering Gear To Frame Nuts (R, V, and G M o d e ls )..............................................

Steering Gear To Frame Nuts (P300(32) andP300(42)FS3)...................................
Steering Gear To Frame Nuts (P200 + 300(42) Excluding FS3).............................
High Pressure Line Fitting (At Gear)...........................................................................
Oil Return Line Fitting (At G e a r)..................................................................................
Pitman Shaft Adjuster Screw Jam N u t.......................................................................
Side Cover To Housing B olt...........................................................................................
Adjuster Plug N u t............................................................................................................
Reservoir Bolt (At P u m p)...............................................................................................
Flow Control Fitting (At P u m p )....................................................................................
Pressure Hose (At P u m p ).............................................................................................
Power Steering Pump To Booster L in e .......................................................................
Booster To Gear L in e ......................................................................................................
Return Line At Booster And G e a r................................................................................
Coupling Flange N u t s ...................................................................................................
Coupling Flange Pinch B o lt..........................................................................................
Lower Intermediate Shaft Pinch Bolt (G M odel).......................................................
Upper Intermediate Shaft Pinch Bolt (G M odel).......................................................
Intermediate Shaft Pinch Bolts (P200 + 300(42) Excluding F S 3 ) ......................
Intermediate Shaft Pinch Bolts (P300(42)FS3).........................................................
TORQUE
N-m
Ft. Lbs.
102
75
108
80
95
70
34
25
34
25
47
35
60
45
110
81
48
35
48
35
27
20
34
25
34
25
34
25
27
20
42
31
62
46
47
35
102
75
108
80
PUMP SPECIFICATIONS
Minimum
Output (1)
Part
Vehicle
Number
Model
GPM
L/Min.
Maximum
Output (2)
Relief Valve Settings

Minimum
Maximum
GPM
L/Min.
PSI
kPa
PSI
kPa
7838933
132-P-122
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7838934
132-P-123
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7838935
132-P-124
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7838936
132-P-125
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839797
132-P-143
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839798
132-P-144
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
R V
7839799
132-P-145
1.32
Model
7839800
132-P-146
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7839801
132-P-147
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7839802
132-P-148
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7839804
132-P-150
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
1350
9998
7839813
132-P-159
1.32
5.00
3.1-3.5
11.7-13.2
9308
1450
7839816
132-P-161
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839818
132-P-163
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
26000518
132-P-260
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7841731
132-P-222
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7842049
132-P-228
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7847616
T115-PT-003
1.15
4.35
7849229
132-P-253
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839808
132-P-154
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
7839809
132-P-155
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
7839812
132-P-158
1.32
5.00
2.4-2.8
9.1-10.6
1350
9308
1450
9998
7839817
132-P-162
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
7842032
132-P-226
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
Model
7842033
132-P-227
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
Model
7842489
132-P-230
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7842490
132-P-231
1.32
5.00
2.4-2.8
9.1-10.6
1350
9308
1450
9998
7842491
132-P-232
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
1 O utput of Power Steering Fluid at 32C (90F) temperature when operating pump at 465 rpm against 4585-5068 kPa
(665-735 psi) pressure.
2 O utput of Power Steering Fluid at 32C (90F) temperature when operating pump at 1500 rpm against 345 kPa (50
psi) pressure.
SPECIAL TOOLS
1. P ow er S te e rin g P ressure T ester
7. P itm a n A rm P u lle r
2. G a ug e A d a p te r 18m m P ow er S te e rin g
8. S n ap R ing P liers #23 In te rn a l
3. T h e rm o m e te r
9. P itm a n S h a ft Seal In s ta lle r
4. P ow er S te e rin g S ystem A n a lyze r
10. B e a rin g P reload S p a n n e r W re nch
5. Pow er S te e rin g A n a ly z e r 18m m A d a p te r
11. W a te r P um p P u lle y R em ove r
6. V-belt U nive rsa l Tension G auge
12. P ow er S te e rin g P u m p P u lle y In s ta lle r

F-02648
3B4-1
SECTION 3B4
STEERIN G COLUMN
The following Notice applies to one or more steps in the assembly procedure of components in this portion of this
m anual as indicated at appropriate locations by the term inology See NOTICE on page 3B4-1 of this section.
NOTICE: All steering column fasteners are important attaching parts in that they could affect the perform ance of
vital com ponents and systems, and/or could result in major repair expense. They must be replaced with one o f the
same part num ber or with an equivalent part if replacem ent becomes necessary. Torque values must be used as
specified during reassembly to assure proper retention o f all parts.
CONTENTS
SUBJECT
PAGE
Description................................................................................................................................................................... 3B4- 2
Diagnosis Of The Steering C olum n.......................................................................................................................... 3B4- 2
Steering Column Electrical Component Analyzer............................................................................................... 3B4-10
Steering Column On-Vehicle Service (All Models)................................................................................................. 3B4-10
Inspection................................................................................................................................................................. 3B4-10
Steering Wheel Replacement.......... ..................................................................................................................3B4-12
Flexible Coupling R eplacem ent............................................................................................................................ 3B4-13
Intermediate Shaft R eplacem ent.......................................................................................................................... 3B4-13
Steering Column On-Vehicle Service (R, V And G M o d e ls ).................................................................................3B4-15
RV Model Steering Column Replacement............................................................................................................3B4-15
G Model Steering Column Replacem ent................................................ .......................................................... 3B4-16
Turn Signal Switch Replacement.......................................................................................................................... 3B4-16
Lock Cylinder Replacem ent.................................................................................................................................. 3B4-17
Tone Alarm Switch Replacement.......................................................................................................................... 3B4-18
Ignition Switch Replacem ent................................................................................................................................ 3B4-18
Standard Steering Column Unit Repair (R, V And G M odels)...............................................................................3B4-19
Standard Steering Column Lower Bearing Adjustm ent.....................................................................................3B4-23
Tilt Steering Column Unit Repair (R, V And G Models)......................................................................................... 3B4-26
Steering Column On-Vehicle Service P(32) Models............................................................................................... 3B4-33
Turn Signal Switch Replacement.......................................................................................................................... 3B4-33
Tilt Steering Column R eplacem ent......................................................................................................................3B4-33
Tilt Steering Column Bearing Housing Replacement......................................................................................... 3B4-35
Tilt Steering Column Unit Repair P(32) M o d els..................................................................................................... 3B4-38
Steering Column On-Vehicle Service P(42) Models............................................................................................... 3B4-38
Standard Steering Column Replacement..............................................................................................................3B4-38
Upper Bearing Replacement.................................................................................................................................. 3B4-39
Lower Bearing Replacement.................................................................................................................................. 3B4-41
Steering Column Lower Bearing A djustm ent..................................................................................................... 3B4-41
Shift Tube A d ju stm e n t..................................... .....................................................................................................3B4-41
Standard Steering Column Unit Repair P(42) M o d e ls........................................................................................... 3B4-42
Intermediate Shaft Unit Repair P(42) M odels......................................................................................................... 3B4-43
S p e cifica tio n s............................................................................................................................................................. 3B4-44
Special T o o ls ............................................................................................................................................................... 3B4-45
3B4-2 STEERING COLUMN
DESCRIPTION
The locking energy absorbing steering column includes
three important features in addition to the steering func
tion:
1. The column is energy absorbing, designed to com
press in a front-end collision to m inimize the possi
bility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted on the col
umn.
3. With the column mounted lock, the ignition, steering
and gearshifting operation can be locked to inhibit
theft of the vehicle.
The column may be disassem bled and reassembled. To

insure the energy absorbing action, it is important that the
specified screws, bolts and nuts be used only as desig
nated and that they are tightened to the specified torque.
When the column is removed from the vehicle, such
actions as a sharp blow on the end of the steering shaft or
shift lever, leaning on the column assembly, or dropping
of the assembly could shear or loosen the plastic fasten
ers that maintain column rigidity.
DIAGNOSIS OF THE STEERING COLUMN

PROBLEM
POSSIBLE CAUSE
Lock System Will Not

Unlock
1.
2.
3.
4.
5.
Lock System Will Not

Lock
1.
2.
3.
4.
5.
6.
Lock SystemHigh
Lock Effort
Lock bolt damaged.

Faulty lock cylinder.
Damaged housing.
Damaged or collapsed sector.
Damaged rack.
CORRECTION
1.
2.
3.
4.
5.
Replace
Replace
Replace
Replace
Replace
Lock bolt spring is broken.

Damaged sector tooth.
Faulty lock cylinder.
Damaged housing.
Damaged rack.
Interference between the bowl and cou
pling.
7. Ignition switch stuck.
8. Actuator rod restricted or bent.
9. Transmission linkage adjustment is in
correct.
1.
2.
3.
4.
5.
6.
Replace the spring.

Replace the sector tooth.
Replace the lock cylinder.
Replace the housing.
Replace the rack.
Adjust or replace.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Lock cylinder is faulty.

Ignition switch is faulty.
Rack preload spring is broken or weak.
Burrs on the sector, rack, housing, sup
port, tang of the shift gate or actuator rod
coupling.
Bent sector shaft.
Distorted rack.
M isalignment of the housing to the cover
(tilt only).
Distorted coupling slot in the rack (tilt
only).
Bent or restricted actuator rod.
Ignition switch m ounting bracket is bent.
the lock bolt.

or repair the lock cylinder.
the housing.
the sector.
the rack.
7. Adjust or replace.
8. Adjust or replace.
9. Adjust.
Replace
Replace
Replace
Remove
the
the
the
the
lock cylinder.
ignition switch.
spring.
burrs.
5. Replace the shaft.

6. Replace the rack.
7. Replace either or both.
9. Straighten or replace the rod.
10. Straighten or replace the bracket.
STEERING COLUMN 3B4-3
DIAGNOSIS OF THE STEERING COLUMN (CONT.)

PROBLEM
POSSIBLE CAUSE
CORRECTION
Lock CylinderHigh
Effort Between The
O ff and Off-Lock
Positions
1. Burr on tang of shift gate.

2. Distorted rack.
1. Remove the burr.

Sticks In Start
Position
1. Actuator rod is deformed.

2. Any high effort condition.
1. Straighten or replace the rod.

2. See correction under the high effort
diagnosis.
Key Cannot Be
Removed In The
Off-Lock Position
1. Ignition switch is not set correctly.

2. Faulty lock cylinder.
1. Adjust ignition switch.

2. Replace the lock cylinder.
The Lock Cylinder

Can Be Removed
Without Depressing
The Retainer
1. Faulty retainer.
2. Burr over the retainer slot in the housing
cover.

2. Remove the burr.
Lock Bolt Hits The

Shaft Lock In The
O ff And Park
Positions
Noise In The Column
Ignition switch is not set correctly.
1. Flexible coupling pulled apart.

2. Column not correctly aligned.
3. One click in O ff-U nlock position and
when the steering wheel is moved.
4. Horn contact ring not lubricated.
5. Lack of grease on the bearings or bear
ing surface.
6. Lower shaft bearing is tight or frozen.
7. Upper shaft bearing is tight or frozen.
8. Lock plate retaining ring is not seated.
9. Steering shaft snap ring is not seated.
10. Shroud or housing is loose.
11. Sheared intermediate shaft plastic joint.
High Steering Shaft

Effort
1. Column assembly is m isaligned in the

vehicle.
2. Tight or frozen upper or lower bearings.
3. Binding intermediate shaft U-joints.
Adjust the ignition switch.
1. Align the column and replace the flexi

ble coupling.
3. Normal seating of the lock bolt.
4. Lubricate.
5. Lubricate the bearings.
6. Replace the bearing. Inspect the shaft
and replace if scored.
7. Replace the housing assembly.
8. Replace the retaining ring. Inspect for
proper seating in the groove.
9. R eplace the snap ring. Inspect for
proper seating in the groove.
10. Tighten mounting screws.
11. Repair or replace the steering shaft.
Align the column.
1. Align correctly.
2. Replace the bearings.
3. R ep air or rep la ce the in te rm e d ia te
shaft.

PROBLEM
High Shift Effort
Improper
Transmission Shifter
POSSIBLE CAUSE
1. Column assembly is misaligned in the
vehicle.
2. Lower bowl bearing is not aligned c o r
rectly.
3. Lack of grease on the bearing or seal a r
eas.
4. Shift tube is bent or broken.
CORRECTION
1. Align correctly.
2. Align correctly.
3. Lubricate bearings and seals.
4. Replace the shift tubes.
1. Sheared shift tube joint.

2. Im proper transm ission linkage adjust
ment.
3. Loose lower shift lever.
4. Sheared lower shift lever weld.
1. Replace the shift tube assembly.

2. Adjust the linkage.
Lash In Mounted
Column Assembly
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Driver Can Lock

Steering In The
Second Gear (Manual
Transmission
Columns)
1. Faulty upper shift lever.

2. Faulty shift lever gate.
3. Loose relay lever on the shift tube.
1. Replace the shift lever.

2. Replace the shift lever gate.
Excessive Play In The

Mounted Steering
Column Assembly
(Tilt Column)
1.
2.
3.
4.
1.
2.
3.
4.
Housing Loose (Tilt

Column)
1. Excessive clearance between the holes

in the support or the housing and pivot
pin diameter.
2. Faulty anti-lash spring in the centering
spheres.
3. Upper bearing not seating in the bearing
race.
4. Upper bearing inner race seat missing.
5. Bearing preload spring broken.
6. Loose support screws.
Housing Scraping On
The Bowl (Tilt
Column)
Column mounting bracket bolts loose.

Broken weld nuts on the jacket.
Column bracket capsule sheared.
Loose shoes in the housing (tilt only).
Loose tilt head pivot pins (tilt only).
Column mounting bracket bolts loose.

Loose support screws.
Loose tilt head pivot pins.
Loose lock shoe pin in the support.
Bowl bent or not concentric with the hub.

Tighten to specifications.
Replace the jacket assembly.
Replace the bracket assembly.
Replace the shoes.
Replace the pivot pins.
Replace the pivot pins.
Replace the pin.
1. Replace either or both.
2. Replace the spring.

3. Replace both.
4. Install the seat.
5. Replace preload spring.
6. Tighten to specifications.
Replace the bowl.

PROBLEM
POSSIBLE CAUSE
CORRECTION
Steering Wheel Loose

Every Other Tilt
Position (Tilt Column)
Loose fit between the lock shoe and

pivot pin.
Steering Column Will

Not Lock In Any Tilt
Position (Tilt Column)
1. Lock shoe grooves may have burrs or

dirt.
2. Lock shoe spring is weak or broken.
3. Lock shoe seized on its pivot pin.
1. R eplace lock shoes and clean the

grooves.
3. Replace both lock shoes.
Noise When Tilting

The Column (Tilt
Column)
1. Tilt spring rubbing in the housing.

2. Tilt bum pers are worn.
1. Lubricate.
2. Replace the tilt bumpers.
Steering Wheel Fails

To Return To The
Top Tilt Position (Tilt
Column)
1. Pivot pins are bound up.

2. Wheel tilt spring is faulty.
3. The turn signal switch wires are too tight.
1. Replace the pivot pins.

3. Reposition the wires.
Dimmer Switch Will

Not Function
1. Loose connector at the dim m er switch.

2. Im proper adjustment.
3. Internally damaged or worn switch.
1. Tighten or replace.
2. Readjust.
3. Replace.
Turn Signal Will Not

Cancel
1. Loose switch mounting screws.

2. Switch or anchor bosses broken.
3. Broken, missing or out of position detent,
return or cancelling spring.
4. Uneven or incorrect cancelling cam to
cancelling spring interference.
1. Tighten screws to 2.8 N m (25 in. lbs.).

2. Replace the switch.
3. Reposition or replace the springs as re
quired.
4. Adjust the switch position.
If the interference is correct and
switch will still not cancel, replace
the switch.
If the interference cannot be cor
rected by the switch adjustment, re
place the cancelling cam.
Turn Signal Difficult

To Operate
1. Actuator rod loose.
1. Tighten mounting screw to 1.4 N-m (12

in. lbs.).
3. Reposition or replace the springs.
4. Remove the foreign parts and/or mate
rial.
5. Tighten mounting screws to 2.8 (25 in.
lbs.).
2. Yoke broken or distorted.

3. Loose or misplaced springs.
4. Foreign parts and/or materials.
5. Switch mounted loosely.

Indicate Lane Change
1. Broken lane change pressure pad or

spring hanger.
2. B roken, m issin g or m is p la c e d lane
change spring.
3. Jammed base or wires.
Replace both.

2. Replace or reposition as required.
3. Loosen m ounting screws, reposition
base or wires and tighten the screws to
2.8 N-m (25 in. lbs.).

PROBLEM
Stay In Turn Position
POSSIBLE CAUSE
1. Foreign material or loose parts impend
ing movement of the yoke.
2. Broken or missing detent or cancelling
springs.
3. None of the above.
Hazard Switch Cannot

Be Turned Off
Hazard Switch Will

Not Stay On Or
Difficult To Turn Off
No Turn Signal Lights
Turn Indicator Lights

On, But Not Flashing
Front Or Rear Turn

Signal Lights Are Not
Flashing
CORRECTION
1. Remove material and/or parts.
Foreign material between hazard sup

port cancelling leg and yoke.
Remove the foreign material.

No foreign m aterial. Replace the turn
signal switch.
1. Loose switch, mounting screws.
1. Tighten m ounting screws to 2.8 N .m
2. Interference with other components.

3. Foreign material.
4. None of the above.
(25 in. lbs.).

2. Remove the interference.
3. Remove the foreign material.
1.
2.
3.
4.
Faulty or blown fuse.

Inoperative turn signal flasher.
Loose chassis to column connector.
Disconnect column to chassis connector.
Connect new switch to chassis and oper
ate switch by hand. If vehicle lights now
operate normally, signal switch is inoper
ative.
5. If vehicle lights do not operate, check
chassis wiring for opens, grounds, etc.
1.
2.
3.
4.
1.
2.
3.
4.
Inoperative turn flasher.

Loose chassis to column connection.
Inoperative turn signal switch.
To determ ine if turn signal switch is
faulty, substitute a new switch into the
circuit and operate the switch by hand. If
the vehicles lights operate normally, the
signal switch is inoperative.
5. If the vehicles lights do not operate,
check light sockets for high resistance
c o n n e c tio n s , the ch a s s is w irin g fo r
opens, grounds, etc.
1.
2.
3.
4.
1. Burned out fuse.

2. Burned out or damaged turn signal bulb.
3. High resistance connection to ground at
the bulb socket.
4. Loose chassis to column connector.
1. Replace fuse and check operation.

2. Replace the bulb.
3. Remove or repair the faulty connection
and check operation.
4. Connect securely and check operation.
Replace
Replace
Connect
Replace
fuse and check operation.

the turn signal flasher.
securely, check operation.
the signal switch.
5. Repair the chassis wiring.
Replace
Connect
Replace
Replace
the turn flasher.

securely and check operation.
the turn signal switch.
the signal switch.

CORRECTION
PROBLEM
POSSIBLE CAUSE
Front Or Rear Turn

Signal Lights Are Not
Flashing (Cont.)
5. Disconnect column to the chassis con

nector. Connect a new switch into the
system and operate the switch by hand.
If turn signal lights are now on and flash,
the turn signal switch is inoperative.
6. If vehicle lights do not operate, check the
chassis wiring harness to light sockets
for opens, grounds, etc.
5. Replace the turn signal switch.
1. Burned out fuse.

2. Loose column to chassis connection.
3. Disconnect column to chassis connector.
Connect new switch into system without
removing old. Operate switch by hand, if
brake lights work with switch in the turn
position, signal switch is faulty.
4. If brake lights do not work, check con
n ecto r to stop lig h t, th e sockets for
grounds, opens, etc.
1. Replace fuse and check operation.

3. Replace the signal switch.
1. Burned out bulbs.

2. High resistance to ground at the bulb
socket.
3. Opens, grounds in wiring harness from
the front turn signal bulb socket to the
indicator lights.
1. Replace the bulbs.

2. Replace the socket.
1. Inoperative turn signal flasher.

2. System charging voltage low.
1. Replace the turn signal flasher.

2. Increase voltage to specifications. Re
fer to (SEC. 6D ENGINE ELECTRICAL)
in this manual.
3. Repair high resistance grounds at the
light sockets.
5. Replace signal switch.
Stop Light Not On

When Turn Indicated
Turn Indicator Panel

Lights Not Flashing
Turn Signal Lights

Flash Very Slowly
3. High resistance ground at light sockets.

4. Loose chassis to column connection.
5. Disconnect column to chassis connector.
removing old. Operate switch by hand. If
flashing occurs at normal rate, the signal
switch is faulty.
6. If the flashing rate is still extremely slow,
check chassis wiring harness from the
connector to the light sockets for high re
sistance.
4. Repair connector to stop lights circuits.
3. Locate and repair as required.
6. Locate and repair as required. Refer to

SEC. 8B (CHASSIS ELECTRICAL) in
this manual.

PROBLEM
Hazard Signal Lights
Will Not FlashTurn
Signal Functions
Normally
Tone Alarm Does Not

Sound With Key Fully
Inserted In Lock
Cylinder With Drivers
Door Open
POSSIBLE CAUSE
1.
2.
3.
4.
CORRECTION
Blown fuse.
Inoperative hazard warning flasher.
Loose chassis to column connection.
Disconnect column to chassis connector.
removing old. Depress the hazard warn
ing button and observe the hazard warn
ing lights. If they now work normally, the
turn signal switch is faulty.
5. If the lights do not flash, check wiring
harness K lead (brown) for open be
tween hazard flasher and harm onica
connector. If open, fuse block is faulty.
1.
2.
3.
4.
1. Loose connection at the tone alarm.

2. Voltage not available to the tone alarm.
1. Connect securely.
2. Check the continuity of the chassis w ir
ing and repair as required.
3. Replace the tone alarm.
4. Adjust or replace as required.
3. Faulty tone alarm.

4. Door jam b switch on the drivers side is
maladjusted or inoperative.
5. Short in the chassis wiring.
6. Short or fault in the signal switch wiring.
7. Chips, burrs, foreign material is prevent

ing actuator tip function. NOTICE: Key
must be removed or the cylinder in the
run position before removing the lock
cylinder.
8. Faulty lock cylinder.
9. Chips, foreign material affecting the tone

alarm switch operation.
10. Damaged or broken tone alarm switch.
11. Inoperative tone alarm switch (switch ap
pears good but will not make the tone
alarm switch function check).
12. Tone alarm switch contact gap is too

large.
Replace
Replace
Connect
Replace
fuse and check operation.

the hazard warning flasher.
securely and check operation.
the turn signal switch.
5. Replace fuse block. Refer to SEC. 8B

(CHASSIS ELECTRICAL) in this man
ual.
5. Check by separating chassis to column

connector. C onnect E and F female
contacts on the chassis side (bent pa
per clip will work). If tone alarm sounds,
continue diagnosis. If not, locate and
repair chassis w iring.
6. Connect male E and F contacts of con
nector with the jumper. Check buzzer
switch pads with the ohmmeter. If con
tact is made, function is normal. If not,
replace the signal switch.
7. Remove chips and burrs. Reassemble
and check.
8. With the lock cylinder out (refer to No

tice under step 7), fully insert and re
move the key. The actuator should
extend and retract smoothly. Total ex
p an sio n of tip s h o u ld be 1.25 mm
(0.050 inch). If not, replace the lock cyl
inder.
9. Remove and clean as required reas
semble and check.
10. Replace the tone alarm switch.
11. C onnect the ohm m eter leads to the
tone alarm switch probes. Press on the
actuator pad until the interior points
contact. If contact is not made, replace
the tone alarm switch.
12. Reset the contact gap.

PROBLEM
POSSIBLE CAUSE
Tone Alarm Does Not 13. If the tone alarm fault has not yet been
detected, connect a continuity meter (or
Sound With Key Fully
light) to the male E and F connector con
Inserted In Lock
Cylinder With Drivers
tacts. Insert the key the full depth into the
lock cylinder. If contact is made with the
Door Open (Cont.)
key in, and is not made with it out, the
function is normal. Retrace the initial di
agnostic steps. If contact is not estab
lished, the fault is in the column.
14. If the fault has not yet been isolated and
repaired, connect ohmmeter to the tone
alarm switch probes. Fully insert and re
move the key from the lock cylinder. If
contact is made with the key in, and is
broken with it out, the function is normal.
Retrace the diagnostic steps. If contact
is not made, the fault is in the lock cylin
der or tone alarm switch.
Tone Alarm Continues 1. Door jam b switch on drivers side malad

justed or inoperative.
To Operate With Key
2. Wire from signal switch to door jamb
In The Lock Cylinder
switch shorted.
With The Drivers
Door Either Opened
Or Closed And Ceases
When Key Is Removed
Tone Alarm Continues

To Operate With Key
Out, But Stops When
Drivers Door Is
Closed
1. Lock cylinder binding (turn lock toward

start position. If tone alarm stops in the
run position or when turned past run run
towards the start, the problem is a sticky
lock cylinder actuator).
2. Chips, foreign material in lock cylinder
bore.
3. Sticky lock cylinder actuator tip.
4. Damaged or broken tone alarm switch.
5. Tone alarm switch contact gap is too
close.
CORRECTION
13. With the fault isolated in the column,
disassem ble the upper end of the col
umn until the signal switch m ounting
screws have been removed. Lift the
switch and check the probes of the
tone alarm switch to ensure good con
tact with the pads in the signal switch.
Bend the probes, if required, then re
seat the signal switch and install the
three screws. Check the function.
14. S e ttin g th e c o n ta c t gap. P re ss a
0.75 mm (0.030 inch) wire type spark
plug gap wire with flat piece of stock on
the actuator pad. If contact is not made,
adjust switch until positive contact is
made (use ohmmeter). With positive
contact at 0.75 mm (0.030 inch) use a
0.65 mm (0.025 inch) plug gap wire be
neath the flat stock. No contact should
occur. Adjust. When the switch will
make contact with the 0.75 mm (0.030
inch) wire and not with the 0.65 mm
(0.025 inch) wire, the tone alarm switch
is set at the low limit.
1. Adjust or replace as required.
2. If on signal switch side, replace signal
switch. If on chassis side, find and re
pair.
This condition indicates the lock cyl
inder or tone alarm switch is at fault. To
verify, check for continuity at the E and
F male connector contacts with the key
removed from the cylinder. If continuity
exists, the fault is in the column.
2. Remove, assemble and recheck func

tion.
4. Replace the tone alarm switch.
5. Adjust as specified.
STEERING COLUMN ON-VEHICLE SERVICE

(ALL MODELS)
INSPECTION
SHIFTER SHAFT
Separation of the shifter shaft sections will be internal
and cannot be visually identified. Hold lower end of the
shifter shaft and move the shift lever on the column
through its ranges and up and down. If there is little or no
movement of the shifter shaft, the plastic joints are
sheared.
STEERING SHAFT
If the steering shaft plastic pins have been sheared, the
shaft will rattle when struck lihtly from the side and some
lash may be felt when rotating the steering wheel while
holding the rag joint. If the steering shaft pins are sheared
due to minor collision w ithout serious damage to other
components, the vehicle can be safely steered; however,
steering shaft replacement is recommended.
1/
^
COLUMN JACKET
Inspect the jacket section of the column for looseness,
and/or bends.
COLUMN SUPPORT BRACKET

Damage in this area will be indicated by separation of
the mounting capsules from the bracket. The bracket will
have moved forward toward the entire com partm ent and
will usually result in collapsing of the jacket section of the
steering column.
A. C a p s u le s m u s t be w ith in 1.59 m m (V ie ")

fro m b o tto m o f s lo ts . If n o t, re p la ce b ra c k e t
a ssem bly.
B T he b o lt head m u s t n o t c o n ta c t s u rfa c e
B. If c o n ta c t is m ade, th e c a p s u le s h e a r
load w ill be in c re a s e d R e p la ce b ra cket.
B-07380
Figure 1Steering Column Collapse Inspection

STEERING COLUMN FOR ACCIDENT DAMAGE
N O T IC E : V e h ic le s in v o lv e d in a c c id e n ts
resulting in frame damage, major body or sheet
m etal damage, or where the steering column
has been im pacted may also have a damaged or
misaligned steering column.
L*
Inspect (Figures 1 through 3)

Capsules on the steering column bracket assembly.
The capsules must be within 1.59 (Vie inch) from the
bottom of the slots (figure 1). If not, the bracket
should be replaced.
2. Contact surface (figure 1). The bolthead must not

contact surface B or the shear load would be
increased. If contact is made, replace the bracket.
3. Shift lever operation on vehicles with automatic
transmission and column shift. If the shift lever is
able to move to the Park position w ithout raising
the lever, the upper shift tube plastic bearing is
broken.
4. Ja cket c o lla p s e . M ea sure th e ja c k e t c o lla p s e
dimensions, depending on the vehicle and steering
column, in either of the following ways (figure 2):
Measure from the end of the bearing assembly
to the lower edge of the upper jacket (C)..
*
'
uq
.-I
*1
-
IO J
Jl
Mr
n
\
*n
I
n
U
C. 346.7 m m (13.64 in c h e s ) RV M O D E L (T ilt

C o lu m n )
D. 72 m m (2.8 in c h e s ) RV M O D E L (S tandard
E. 353 m m (14 in c h e s ) RV M O D E L (S tandard
C o lu m n -F lo o r S h ift)
1 J
F. 81.7 m m (3.21 in ch e s) G M O D E L (T ilt C o l

u m n -C o lu m n S h ift)
G. 144.9 m m (5.70 in ch e s) G M O D E L (T ilt C o l
um n-4 Speed)
H. 192 m m (7.5 in ch e s) G M O D E L (S tandard
J. 80 m m (3.1 in c h e s ) G M O D E L (T ilt C o lu m n F lo o r S h ift)
F-02585

,K
tE
K. In s p e c t fo r sh ea re d in je c te d p la s tic in th e
s h ift tu b e .
L. In s p e c t fo r sh e a re d in je c te d p la s tic in th e
s te e rin g s h a ft.
B-07382

Measure from the collar on the toe plate flange
to the lower edge of the upper jacket (E, G and
H).
Measure from the edge of the back-up switch
window to the lower edge of the upper jacket
(D, F and J).
The turn signal control assem bly must be in the

neutral position when assem bling the steering
wheel.
1. Steering wheel onto the steering shaft. Align the
marks made at removal.
Im portant
If the jacket dim ensions are not within specifications, a

new jacket must be installed.
Visually inspect for sheared injected plastic in
the shift tube, and the steering shaft (figure 3).
If either one or both are sheared, replace with
new parts.
5. Any frame dam age that could cause a bent
steering shaft must have the steering shaft
run ou t checked in the fo llo w in g m anner:
R em ove in te rm e d ia te shaft. H old a ruler
against the lower end of steering shaft and
have the steering wheel rotated. The runout
must not exceed 1.59 mm (Vie inch). A dial
indicator may be used instead of a ruler.
Do not misalign the steering wheel more than

25.4 mm (1 inch) from the horizontal centerline
(figure 5).
2. Horn lead assembly (some models).
3. Steering wheel nut.
Tighten
4. Retainer.
5. Horn button cap.
STEERING WHEEL REPLACEMENT

Tools Required:
J-1859-03 Steering Wheel Puller
2. Horn button cap.
3. Retainer and steering wheel nut.
4. Horn lead assem bly (some models).
Mark the relationship of the steering wheel to the
steering shaft.
5. Steering wheel. Use J-1859-03 (figure 4). Do not
hammer on the puller, or damage could result to the
steering column.

NOTICE: For step 3 see N o tic e on page
3B4-1.
A. Do n o t m is a lig n m ore th a n 25.4 m m (1 inch)

fro m th e v e rtic a l c e n te rlin e .
F-02675
Figure 5Steering Wheel Alignment

!, Measure
Coupling to flange dimension. Maintain a 6.4
to 9.5 mm (0.250 to 0.375 inch) dimension.
INTERMEDIATE SHAFT
REPLACEMENT
1 . C la m p B o lt
2. N u ts A nd W ashers
A.
B.
C.
D.
C a p tu rin g S trap
A lig n m e n t P ins
W afer
B-07385
Figure 6Flexible Type Steering Coupling
Set front wheels in the straight ahead position.

Mark the upper universal joint yoke to steering shaft
and the lower yoke to steering gear worm shaft
relationship.
1. Upper and lower universal yoke pinch bolt.
2. Steering gear frame bolts. Lower the steering gear.
It is not necessary to disconnect the pitman

arm from the steering gear pitman shaft.
3. Interm ediate steering shaft and universal jo in t
assembly.
+ 4-
FLEXIBLE COUPLING
REPLACEMENT
1. Coupling to flange bolt nuts and washers (2).
2. Clamp bolt (1).
3. Steering gear frame bolts. Lower the steering gear
far enough to remove the flexible coupling.
4. Flexible coupling from the steering gear wormshaft.
Tap lightly with a soft mallet.
NOTICE: For steps 2, 3 and 4 see
page 3B4-1.
N otice on
1. Flexible coupling onto the steering gear wormshaft.

Align the flat on the shaft with the flat in the
coupling.
Push the coupling onto the wormshaft until the
coupling reinforcement bottoms against the
end of the worm.
2. Clamp bolt (1) into the split clamp. The bolt must
Tighten
Place the steering gear into position, guiding
the flexible coupling bolts into the proper holes
in the steering shaft flange.
3. Steering gear and frame bolts.
Tighten
Bolts to Specifications at the end of this
section.
4. Coupling to flange bolt nuts and washers (2).
The c o u p lin g a lig n m e n t p in s s h o u ld be
centered in the flange slots.
Tighten
NOTICE: For steps 2, 3 and 4 see N otice on

page 3B4-1.
1. Intermediate shaft lower yoke onto the steering gear
wormshaft. Align the marks made at removal.
2. Pinch bolt. The pinch bolt must pass through the
shaft undercut.
Tighten
Pinch bolt to Specifications at the end of
this section.
Raise the steering gear into position while guiding
the upper yoke assembly onto the steering shaft.
The marks on the coupling and steering shaft must
align.
3. Steering gear and frame bolts.
Bolt to Specifications at the end of this

section.
4. Pinch bolt to the upper yoke assembly. The pinch
bolt must pass through the shaft undercut.
Tighten
this section.
Measure (Figure 8)
Carden joint operating angle (G-Model). The
angle must not exceed 39 degrees maximum
or 34 degrees minimum.
Figure 7Intermediate Shaft Installation
*F R T
A. A n g le m u s t n o t e xce e d 39 d e g re e s m a x im u m
o r 34 d e g re e s m in im u m .
B-07387
Figure 8Carden Joint Angle (G-Model)

(R, V AND G MODELS)
7. Transmission indicator cable (some models).
8. Screws (6), upper cover (3), lower cover (5), and seal
(4).
9. Screws (7), nuts (8) and bracket (9).
10. Steering column assembly. Rotate the column so
the shift lever clears the dash opening.

page 3B4-1.
1. Plastic spacers onto the flexible coupling alignm ent
pins.
2. Lower end of the steering column through the dash
opening.
3. Lower s te e rin g s h a ft fla n g e onto the fle x ib le
coupling (13).
4. Flange to coupling washers and nuts (1).
Tighten
The flexible coupling (13) on manual steering must
be installed prior to column installation.
5. Screws (7) and (8) and bracket (9) loosely. Tighten
screws and nuts finger tight.
6. Clamp (11) and nuts (10).
2.
3.
4.
5.
6.
7.
8.
N u ts A n d W ashers
U p p e r C over
Seal
L o w e r C over
S cre w s
S cre w s
N u ts
9.
10.
11.
12.
13.
B ra cket
N u ts
C la m p
Pot J o in t
F le x ib le C o u p lin g
Tighten
Nuts (10) to 24 N-m (18 ft. lbs.).

Screws (7) and nuts (8) to 30 N m (22 ft. lbs.).
7. Seal (4) and covers (3, 5) to the dash.
8. Screws (6).
B-07388
Remove plastic spacers from the flexible

coupling pins.
Figure 9Steering Column Installation (RV Model)

Measure
RV MODEL STEERING
COLUMN REPLACEMENT
Transmission control linkage from the column shift
tube levers.
Nuts and washers (1) that secure the flanged end of
the steering shaft to the flexible coupling.
Nuts (10) and clamp (11).
S te e rin g w h e e l. R e fe r to S te e rin g W h e e l
R eplacem ent in this section.
Steering column harness at the connector.
D is c o n n e c t th e n e u tra l-s ta rt sw itc h and
b a c k -u p la m p s w itc h c o n n e c to rs (som e
m o d e ls ). R e fe r to SEC. 8B (C H A S S IS
ELECTRICAL) in this manual.
Pot joint (12) operating angle must not exceed

12 degrees.
Flexible coupling (13) must not be distorted
greater than 1.5 mm (0.06 inch) due to pot
joint bottoming, in either direction.
10. Transmission indicator cable (some models).
11. Connectors to the steering column harness.
Connect the neutral-start switch and back-up
iamp switch connectors (some models). Refer
to SEC. 8B (CHASSIS ELECTRICAL) in this
manual.
12. S te e rin g w h e e l. R e fe r to
13. Transmission control linkage.
S te e rin g
W heel
Guide the steering shaft into the universal yoke,

lining up the marks made at removal.
3. Upper universal joint pinch bolt (14). The pinch bolt
must pass through the shaft undercut.
&
xnU i
6.
7.
8.
9.
14.
Pinch bolt to 47 N-m (35 ft. lbs.).
S cre w s
S cre w s
N u ts
B ra cket
P in ch B o lt
B-07389
Figure 10Steering Column Installation (G Model)
G MODEL STEERING COLUMN

REPLACEMENT
2. Transmission control linkage from the column shift
tube levers.
3. U pper universal jo in t pinch bolt (14) from the
interm ediate shaft. Mark the relationship of the
universal yoke to the steering shaft.
4. Screws (7), nuts (8) and bracket (9).
5. Screws (6) from the cover and seal.
6. S te e rin g w h e e l. R e fe r to S te e rin g W h e e l
7. Steering column harness at the connectors.
D is c o n n e c t th e n e u tra l-s ta rt s w itc h and
b a c k -u p la m p s w itc h c o n n e c to rs (so m e
m o d e ls ). R e fe r to SEC. 8B (C H A S S IS
ELECTRICAL) in this manual.
8 . Steering column assembly. Rotate the column so
the shift lever clears the dash opening.

page3B4-1.
Tighten
see
Measure
Carden joint operating angle. The angle must
not exceed 39 d e g re e s m axim um or 34
degrees minimum (figure 8).
Tighten
Screws (7) and nuts (8) to 30 N-m (22 ft. lbs.).
3. Screws (6) through the cover and seal to the dash
panel.
4. Connectors to the steering column harness.
Connect the neutral-start switch and back-up
lamp switch connectors (some models). Refer
to SEC. 8B (CHASSIS ELECTRICAL) in this
manual.
S te e rin g
W heel
6. Transmission control linkage.

7. Batter ground cable.
TURN SIGNAL SWITCH

REPLACEMENT
Tools Required:
J-23653-A Lock Plate Com pressor
S te e rin g
W heel
2. Instrument panel trim cover.
Notice on
1. Lower end of the steering column through the dash

opening.
2. Bracket (9), screws (7) and nuts (8) loosely. Tighten
screws and nuts finger tight.
Position a screwdriver blade into the steering shaft

lock plate cover slot. Pry up and out to free the cover
from the lock plate.
Screw the ce nte r
steering shaft as far
plate by turning the
the retaining ring
Remove J-23653-A.
post of J-23653-A onto the

as it will go. Compress the lock
center post nut clockwise. Pry
out of the sh aft (figure 11).
Im portant
Important
Use only the specified screws, bolts and nuts

at assembly. The use of overlength screws
could prevent a portion of the assembly from
compressing under impact.
If the column is being disassembled on a

bench, the shaft could slide out of the end of
th e m ast ja c k e t w he n th e sn ap rin g is
removed.
3. Lock plate.
4. Turn signal lever screw and lever.
6. Hazard warning knob. Press the knob inward and
then unscrew.
7. Turn signal mounting screws.
Pull the switch connector out of the bracket on the
jacket and feed switch connector through column
support bracket and pull switch straight up, guiding
the wiring harness through the column housing and
protector.
On non-tilt columns, be sure the wiring harness is

on the protector. Feed the connector and cover
down through the housing and under the mounting
bracket.
On tilt columns, feed the connector down through
the housing and under the mounting bracket. Install
the cover on the harness.
1. Turn signal mounting screws.
Clip the connector to the bracket on the jacket.
Instrument panel trim plate.
8. Wire protector. Pull downward out of the column with

pliers using the tab provided (figure 12).
Hazard warning knob.

Turn signal lever and screws.
Position the turn signal and shifter housing in the

lo w position. Remove the harness cover by
pulling toward the lower end of the column, be
careful not to damage the wires (tilt column).
9. Turn signal switch. Pull the switch straight up,
guiding the wiring harness and cover through the
column housing (figure 13).
Put the turn signal switch in the N eutral position.

Pull o ut on the hazard warning knob.
W a sh e r, u p p e r b e a rin g p re lo a d s p rin g a nd
cancelling cam onto the upper end of the shaft.
6 . Lock plate onto the end of the shaft.
Screw the center post of J-23653-A onto the
steering shaft as far as it will go. Place a NEW
retaining ring over the center post. Place the
C bar over the c e n te r p ost and th en
compress the lock plate by turning the nut
clockwise. Slide the new retaining ring down
the tapered center post and into the shaft
groove (figure 14). Remove J-23653-A.

Tools Required:
J-23653-A Lock Plate Compressor
Cover on the lock plate and snap into position.

S te e rin g w h e e l. R e fe r to
S te e rin g
W heel
LOCK CYLINDER REPLACEMENT
++
Place the lock cylinder in the Run position.

S te e rin g
W heel
2. Turn signal switch. Refer to Turn Signal Switch


TONE ALARM SWITCH
REPLACEMENT
Pull the turn signal switch up far enough to
allow access to the tone alarm switch. Refer to
Turn Signal Switch R eplacem ent in this
section.
The tone alarm sw itch m ay be rem oved
w ithout removing the lock cylinder. The lock
cylinder must be in the Run position.
2. Tone alarm switch assembly.
Pull the tone alarm switch straight out of the
housing using a paper clip or similar tool. A
flat spring wedges the switch toward the lock
cylinder.
Im portant
A. Hold the lo ck c y lin d e r sleeve and rotate the
knob c lo c k w is e against the stop.
B. Lock C ylin de r Set
C. C ylinder Key
D. Lock R etaining Screw
Be careful not to let the flat spring fall down

into the housing and do not pull on the switch
contacts or plastic material of the switch when
removing.
Install or Connect
B-07394
Figure 15Lock Cylinder Installation

It is not necessary to completely remove the
turn signal switch from the column. Pull the
switch rearward far enough to slip it oyer the
end of the shift. Do not pull the harness out of
the column.
3. Retaining screw and the lock cylinder set.
Im portant
If the retaining screw is dropped on removal, it
c o u ld fa ll in to th e c o lu m n , re q u irin g a
complete disassem bly to retrieve the screw.
1. Lock cylinder set.
Align he cylinder key with the keyway in the
housing. Rotate as shown in figure 15.
Push the lock all the way in.
2. Retaining screw.
1. Tone alarm switch to the spring clip with the formed

end of the clip around the lower end of the switch.
The spring is bowed away from the switch.
Lay the spring on the switch opposite the
contacts.
2. Tone alarm switch and spring into the hole with the
contacts toward the lock cylinder bore.
4. S te e rin g W h e e l. R e fe r to S te e rin g W h e e l
IGNITION SWITCH REPLACEMENT

The ignition switch is mounted on top of the column
jacket near the front of the dash. For anti-theft reasons,
the switch is located inside the channel section of the
brake pedal support.
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on the
end of the lock cylinder. This enables the rod and rack to
be moved axially (with respect to the column) to actuate
the switch when the lock cylinder is rotated.
Tighten
S crew to 4.5 N m (40 in. lbs.) (N o n -T ilt
Columns).
Screw to 2.5 N m (22 in. lbs.) (Tilt Columns).

S te e rin g
W heel
Lower the steering column. Refer to CK Model or G

M odel S tee rin g C olum n R e p la c e m e n t in th is
section. It is not necessary to remove the steering
wheel.
Im portant
Properly support the steering column if it is not
removed from the vehicle.
Put the ignition switch in the Lock position.

If the lock cylinder was removed, the actuating
rod to the switch should be pulled up until
there is a definite stop, then moved down one
detent, which is the Lock position.
1. Two ignition switch screws.
2. Ignition switch assembly.
*+ Install or Connect (Figure 16)

Put the ignition switch in the Lock position (figure
16).
1. Activating rod into the ignition switch.
2. Ignition switch and screws to the column.
3. S teering colum n assem bly. Refer to Steering
Column Replacement in this section.
A
A. S w itc h In T he L o ck P o s itio n
B-07395
Figure 16Ignition Switch Assembly
STANDARD STEERING COLUMN UNIT REPAIR

(R, V AND G MODELS)
++
Steering column assembly. Refer to RV or G Model
Steering Column Replacem ent in this section.
Disassemble (Figures 17 through 25)
3.
4.
5.
6.
Dash panel bracket and screws from the column.

Clamp the steering column in a vise.
Clamp at the lower end of the jacket.
Steering wheel. Refer to Steering Wheel Replace
m ent in this section.
Turn signal switch. Refer to Turn Signal Switch Re
placem ent in this section.
Lock cylinder. Refer to Lock Cylinder Replace
Tone alarm switch, if it needs to be serviced. Refer
to Tone Alarm Switch R eplacem ent in this sec
tion.
Im portant
7.
8.
9.
10.
11.
12.
13.
14.
The buzzer switch does not have to be re

moved to remove the upper bearing housing.
Ignition switch. Refer to Ignition Switch Replace
S h ift lever pivot pin and lever. (C olum n S h ift
Models).
Upper bearing washer.
Screws attaching the turn signal and ignition lock
housing.
Housing assembly (figure 23).
Bushing and retainer from the lower side of the
housing.
Ignition switch actuating rod, rack assembly, rack
preload spring, shaft lock bolt and spring assembly
from the housing.
Shift lever detent plate.
15. Ignition switch actuator sector through the lock cyl

inder hole by pushing firm ly on the block tooth of the
sector with a blunt punch or screwdriver (figure 24).
16. Gear shift lever housing and shroud from the jacket
assembly.
On floor shift models remove the transmission
control lock tube housing and shroud.
. Shift lever spring from the gear shift lever housing.
On floor shift models remove the lock tube
spring.
18. Steering shaft from the lower end of the jacket as
sembly.
19. Back-up switch or neutral-safety switch. Refer to
SEC. 8B (CHASSIS ELECTRICAL) in this manual.
20 . Lower bearing retaining clip (figure 25).
On Automatic and Floorshift Columns.
Remove the lower bearing retainer, bearing
a d a p te r assem bly, s h ift tu b e s p rin g and
washer. The lower bearing may be removed
from the adapter by light pressure on the bear
ing outer race.
Slide out the shift tube assembly.
On Manual Transmission (Column Shift)
Remove the lower bearing adapter, bearing
and the first reverse shift lever. The lower bear
ing may be removed from the adapter by light
pressure on the bearing outer race.
Remove the three screws from the bearing at
the lower and slide out the shift tube assem
bly.
Remove the gear shift housing lower bearing
from the upper end of the mast jacket.
17
Assemble (Figures 17 through 22, 26 and 27)

Apply a thin coat of lithium grease to all friction sur
faces.
48
4*
49 I 47
B-07396
Figure 17Standard Steering ColumnColumn Shift (RV Model)

20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
41.
42.
43.
44.
45.
46.
R e ta in e r
N ut
L o ck P late C over
R e ta in e r
L o c k Plate
C a n c e llin g C am
B e a rin g Preload S p rin g
Turn S ig na l S cre w s
Tap S crew
A c tu a to r A rm
Turn S ig na l S w itc h
Turn S ig n a l H o u s in g S cre w s
W a sh er
Tone A la rm S w itc h
R e ta in e r C lip
R e ta in e r S crew
Ig n itio n L ock
A c tu a to r S e c to r
H o u s in g A s s e m b ly
B e aring
B u s h in g
H o rn C o n ta c t
U p p e r B e aring R e ta in e r
D im m e r P ivot A n d
W ip e r S w itc h
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
73.
74.
75.
76.
S h a ft L o c k B o lt
S w itc h R ack P reload S p rin g
A c tu a to r R ack
A c tu a to r P ivot Pin
W asher
S h ift Lever G ate
S h ift Lever S crew
H o u s in g C ove r
C ove r S cre w
S h ift Lever S p rin g
G ear S h ift H o u s in g
G ear S h ift S h rou d
W a sh e r
G ear S h ift H o u s in g B e aring
Jacket
W irin g P ro te c to r
A c tu a to r Rod
D im m e r S w itc h
Ig n itio n S w itc h S crew
Ig n itio n S w itc h
Dash Seal
S h a ft
S h ift Tube
W asher
S p rin g
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
A d a p te r
A d a p te r C lip
L o w e r B e aring
A u to m a tic T ra n s m is s io n
S h ift Tube
B o lt
S p a ce r
L ow er S h ift Lever
A d a p te r P late
A d a p te r
R e ta in e r
A d a p te r C lip
M an ua l T ra n s m is s io n
B o lt
N ut
C o u p lin g
R e ta in e r
B e aring
S p rin g
W asher
Pin
Seal
In te rm e d ia te S h a ft
B-07361
Figure 18Standard Steering ColumnColumn Shift (RV Model)

1. Sector into the turn signal and lock cylinder hous
ing.
Install the sector in the lock cylinder hole over
the sector shaft w ith the tang end to the out
side of the hole.
Press the sector over the shaft with a blunt
tool.
2. Shift lever detent plate onto the housing.
3. Rack preload spring into the housing from the bot
tom side. The long section should be toward the
handwheel and hook onto the edge of the housing
(figure 26).
4. Locking bolt onto the crossover arm on the rack and
insert the rack and lock bolt assem bly into the hous
ing from the bottom with the teeth up (toward hand
wheel) and toward the centerline of the column.
Align the first tooth on the sector with the first
tooth on the rack; if aligned properly, the block
teeth will line up when the rack assembly is
pushed all the way in.
5. Retainer and bushing.
6. Gear shift housing lower bearing. Insert the bearing
from the very end of the jacket.
Align the indentations in the bearing with the
projections on the jacket (figure 27). If the
bearing is not installed correctly, it will not rest
on the stops provided.
7. Shift lever spring into the gear shift lever (or lock
tube) housing.
8. Housing and shroud assemblies onto the upper end
of the mast jacket.
9.
10.
11.
Rotate the housing to be sure it is seated in

the bearing.
Turn signal and lock cylinder housing onto the
jacket.
The gear shift housing should be in the Park
position and the rack pulled downward.
Seat the turn signal housing and install the
four screws.
Lower bearing into the adapter assembly.
Shift tube assem bly into the lower end of the jacket.
Rotate until the upper shift tube key slides into the
housing keyway.
On Automatic and Floor Shift Columns
Install the spring and lower bearing adapter
assembly into the bottom of the jacket.
Hold the adapter in place and install the lower
bearing reinforcem ent and retainer clip. The
clip snaps into the jacket and reinforcem ent
slots.
On Manual Transmission (Column Shift)
Loosely attach the three screws in the jacket
and shift tube bearing.
Assem ble the first reverse lever, lower bearing
and adapter assembly into the bottom of the
jacket.
Hold the adapter in place and install the bear
ing reinforcement and retaining clip. The clip
snaps into the jacket and reinforcem ent slots.
Adjust the lower bearing. Refer to the Manual
Transmission (Column Shift) Lower Bearing
Figure 19Standard Steering Column (RV Model)
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
R e ta in e r
N ut
L o ck P late C over
R e ta in e r
L o ck Plate
C a n c e llin g Cam
B e aring P reload S p rin g
Tap S crew
A c tu a to r A rm
Turn S ig na l H o u s in g S cre w s
W a sh er
R e ta in e r C lip
R e ta in e r S crew
Ig n itio n L ock
Key R elease S p rin g
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
57.
58.
59.
62.
63.
64.
Key R elease Lever

Key R elease W a sh er
B e aring
B u s h in g
H orn C o n ta c t
U p p e r B e a rin g R e ta in e r
D im m e r P ivo t A n d W ip e r S w itc h
S h a ft L o ck B o lt
S w itc h R ack P reload S p rin g
A c tu a to r R ack
W asher
G e a r S h ift H o u s in g
S ig n a l S w itc h M o u n tin g S c re w s
G e a r S h ift H o u s in g
Jacket
A c tu a to r Rod
65.
66.
67.
68.
69.
70.
71.
72.
73.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
Ig n itio n S w itc h S cre w
Dash Seal
A d a p te r
B e aring
A d a p te r C lip
S h a ft
B o lt
N ut
C o u p lin g
R e ta in e r
B e aring
S p rin g
W a sh er
Pin
Seal
In te rm e d ia te S h a ft
B-07362
Figure 20Standard Steering Column (RV Model)

12. Back-up switch or neutral-safety switch. Refer to
SEC. 8B (CHASSIS ELECTRICAL) in this manual.
13. Steering shaft into the column.
14. Upper bearing washer.
15. Ignition switch. Refer to Ignition Switch Replace
16. Tone alarm switch, if removed. Refer to Tone Alarm
Switch R eplacem ent in this section.
STANDARD STEERING COLUMN

LOWER BEARING ADJUSTMENT
MANUAL TRANSMISSION (COLUMN SHIFT)
A djust (Figure 28)
1. Put the transm ission in neutral and disconnect the
transm ission rods.
2. Test for rotational drag by turning the shift lever
through the 2 -3 shift arc. The drag measured must
not be more than 9N (2 lbs.).
3. Loosen the three clam ping screws.
17. Lock cylinder. Refer to Lock Cylinder Replace

18. Turn signal switch. Refer to Turn Signal Switch Re
19. Steering wheel. Refer to Steering Wheel Replace
20. Shift lever and pivot pin.
Remove the column from the vise.
21. Dash panel bracket and screws to the column.
Increase clearance by sliding the clam ping

screws in the direction of arrow B until the
first reverse lever is free of drag (figure 28).
Decrease clearance by sliding the clam ping
screws in the direction of arrow A until a
slight drag is felt at the first reverse shift lever
(figure 28).
4. Install a 0.13 mm (0.005 inch) thick shim between
the space and either of the shift levers.
5. Slide the clam ping screws in the direction of arrow
B until the system is loose. Slide the screws in the
opposite direction until a drag is felt at the first
reverse shift lever.
6. Tighten the clam ping screws.
Install or Connect
7. Remove the shim.

Steering Column R eplacem ent in this section.
8. Install the transm ission rods.
Figure 21Standard Steering Column (G Model)
20. R e ta in e r
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Nut
Lock Plate Cover
Retainer
Lock Plate
C ancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
A ctu a to r Arm
Turn Signal S w itch
Turn Signal H ousing Screws
W asher
Tone Alarm S w itch
R etainer C lip
R etainer Screw
Ig n ition Lock
A ctua tor S ector
Key Release Spring
Key Release Lever
Key Release W asher
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
B e aring
B u s h in g
H orn C o n ta c t
U p p e r B e a rin g R e ta in e r
D im m e r P ivot A n d
W ip e r S w itc h
S h a ft L o c k B o lt
S w itc h R ack Preload S p rin g
A c tu a to r R ack
W a sh er
S h ift Lever G ate
S h ift Lever S crew
H o u s in g C over
C ove r S cre w
S h ift Lever S p rin g
G ear S h ift H o u s in g
S ig n a l S w itc h M o u n tin g
S c re w s
G ear S h ift S h rou d
61. G e ar S h ift H o u s in g
B e aring
62.
63.
64.
65.
66.
67.
68.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
Jacket
A c tu a to r Rod
Ig n itio n S w itc h S crew
Dash Seal
S h ift Tube
W a sh er
S p rin g
A d a p te r
B e aring
A d a p te r C lip
S h a ft
B e a rin g W a sh er
R e ta in e r
M an ua l T ra n s m is s io n
B-07364
Figure 22Standard Steering Column (G Model)
B-07400
Figure 24Ignition Switch Actuator Sector Removal
Figure 23Turn Signal Housing Removal
B-07401
Figure 25Lower Bearing Retainer Removal
80 88
Figure 26Rack Preload Spring Installtion
62. Jacket
80. Lower
Bearing
83. Bolt
84. Spacer
85. Lower S h ift
Lever
88. Retainer
89. Adapter C lip
C. 2 -3 S h ift Lever
D. Shim 0.13 mm (0.005 inch)
B-07404
Figure 28Lower Bearing Adjustment
Figure 27Gearshift Housing Lower Bearing

Installation
TILT STEERING COLUMN UNIT REPAIR

(R, V AND G MODELS)
| ? | Im portant

Disassemble (Figures 29 through 36)

Tools Required:
J-22635 Lock Shoe and Release Lever Pin Re
mover and Installer
J-21854-01 Pivot Pin Remover
J-23072 Shift Tube Remover
10.
1. Dash panel bracket and screws from the column.

2. Clamp the steering column in a vise.
11.
12.

5. Tone alarm switch, if it needs to be serviced. Refer
to Tone Alarm Switch Replacement in this sec
tion.
13.
14.
The tone alarm switch does not have to be re

moved to remove the upper bearing housing.
Ignition switch. Refer to Ignition Switch Replace
Tilt release lever.
Shift lever pivot pin and lever.
Housing cover screws and housing cover.
Install the tilt release lever and place the column in
the up position.
Tilt lever spring retainer, spring and guide. Use a
screwdriver to turn the retainer until it aligns with the
grooves in the housing then remove the retainer.
Pot joint to steering shaft clam p bolt and remove the
interm ediate shaft and pot jo in t assem bly (RV
Model).
Upper bearing inner race and seat. Push the upper
steering shaft in enough to remove the race and
seat.
Lower bearing retainer clip.
Bearing reinforcement, bearing and bearing adapter
assembly from the lower end of the mast jacket.

15. Upper bearing housing pivot pins. Use J-21854-01
(figure 33).
Install the tilt release lever and disengage the lock
shoes.
16. Bearing housing by pulling upward to extend the
rack full down, and then moving the housing to the
left to disengage the ignition switch rack from the
actuator rod.
17. Steering shaft assembly from the upper end of the
column.
18. Steering shaft by removing the centering spheres
and the anti-lash spring.
19. Transmission indicator wire, if so equipped.
20. B earing housing su p p o rt to g e a rsh ift housing
screws and remove the bearing housing support.
21. Ignition switch actuator rod.
22. Shift tube retaining ring and washer.
NOTICE: When removing the shift tube, be sure
to guide the low er end through the slotted
opening in the mast jacket. If the tube is al
lowed to interfere with the jacket in any way,
damage to the tube and jacket could result.
Install J-23072 into the lock plate, making sure that
the tool screws have good thread engagem ent in
the lock plate. Then, turning the center screw clock
wise, force the shift tube from the housing (Figure
34). Remove the shift tube (transmission control
lock tube on floor shift models) from the lower end of
the mast jacket. Remove J-23072.
23. Lock plate and washer.
Slide the lock plate out of the jacket notches
by tipping it down toward the housing hub and
sliding it under the jacket opening.
24 Shift lever housing from the mast jacket. (Transmis
sion control lock tube housing on floor shift models).
Place the housing on a work bench and with a

pointed punch against the back surface of the
race, carefully hammer the race out of the
housing until a bearing puller can be used.
Repeat for the other race.
Assemble (Figures 29 through 39)

Tools Required:
J-23073-01 Shift Tube Installer
J-22635 Lock Shoe and Release Lever Pin Re
mover and Installer
If the bearing housing was disassembled, repeat
steps 1-9.
faces.
Bearings into the bearing housing, if removed.
Lock shoe springs, lock shoes and shoe pin in the
bearing housing. Use J-22635 or a 4.5 mm (0.180
inch) diameter rod to line up the shoes for pin instal
lation.
3. Release lever, spring and pin.
Im portant
To relieve the load on the release lever, hold
the shoes inward and wedge a block between
the top of the shoes (over slots) and bearing
housing.
Sector drive shaft into the housing.
Lightly tap the sector onto the shaft far enough
to install the snap ring.
Snap ring.
Lock bolt. Engage the bolt with the sector cam sur
face.
Rack and spring. The block tooth on the rack should
engage the block tooth on the sector (figure 37).
8. Tilt release lever.
9. Lock bolt spring and retaining screw.
Disassemble the bearing housing as follows:

25. Tilt lever opening shield.
26 Lock bolt spring. Remove the retaining screws and
move the spring clockwise to remove it from the bolt
(figure 35).
27. Snap ring from the sector drive shaft.
With a small punch, lightly tap the drive shaft
from the sector (figure 36).
28. Drive shaft, sector and lock bolt.
29. Rack and rack spring.
30. Tilt release lever pin. Use J-22635.
31. Release lever and spring.
Im portant
To relieve the load on the release lever, hold
the shoes inward and wedge a block between
the top of the shoes (over slots) and bearing
housing.
32. Lock shoe retaining pin. Use J-22635.
33. Lock shoes and springs.
34. Bearings from the bearing housing only if they are
to be replaced.
Remove the separator and balls from the bear
ings.
Tighten
Screw to 4 N-m (35 in. lbs.).
10. Shift lever spring into the housing. Wind the spring
up with pliers and push it into the housing.
On floor shift models, install the plunger and
slide the gearshift lever housing onto the mast
jacket.
11. Washer and lock plate. Slide the lock plate into the
notches in the jacket.
NOTICE: Do not push or tap on the end o f the
shift tube. Be sure that teh shift tube lever is
aligned with the slotted opening at the lower
end of the mast jacket or damage to the shift
tube and mast jacket could result.
12. Shift tube into the lower end of the mast jacket.
Align the keyway in the tube with the key in the
shift lever housing.
Install the wobble plate end of J-23073-01 into
the upper end of the shift tube far enough to
reach the enlarged portion of the tube.
Install the adapter over the end of the tool,
seating it against the lock plate.
Figure 29Tilt Steering Column (RV and G Models)

120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
R e ta in e r
N ut
Lock P late C over
R e ta in e r
L o ck P late
B e aring P reload S p rin g
Tap S crew
A c tu a to r Arm
Turn S ignal S w itc h
In n e r Race Seat
B e aring Race
S crew
R e ta in e r C lip
L ock R e ta in e r S crew
Ig n itio n Lock
H o u s in g C over
D im m e r S w itc h A c tu a to r
S h ie ld
Pin Preload S p rin g
P ivot S w itc h
Cap
R e ta in e r
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
172.
173.
T ilt S p rin g
S p rin g G u id e
S cre w
B e aring
L o c k B o lt
L o ck B o lt S p rin g
L o ck S hoe
L o ck S hoe
S e c to r S h a ft
L o c k S h oe Pin
P ivot Pin
S h oe R elease S p rin g s
S p rin g
S h oe R elease Lever Pin
S h oe R elease Lever
L o w e r B e aring
R ack P reload S p rin g
A c tu a to r R ack
Ig n itio n S w itc h A c tu a to r
S p he re S p rin g
C e n te rin g S p he res
S p rin g
L o w e r S te e rin g S h a ft
H o u s in g S u p p o rt S cre w s
174.
175.
176.
177.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
193.
194.
195.
196.
197.
198.
H o u s in g S u p p o rt
Pin
S h ift Lever G ate
D e te n t P la te S cre w
W a sh er
L ock Plate
W ave W a sh er
G ear S h ift Lever S p rin g
G ear S h ift Lever B ow l
S h rou d
S crew
S tud
S w itc h
D im m e r S w itc h Rod
N ut
Jacket
Dash Seal
S h ift Tube
A d a p te r
L o w e r B earing
R e ta in e r
A d a p te r C lip
B-07365
Figure 30Tilt Steering Column(TV and G Models)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Place the nut on the threaded end of the tool

and pull the shift tube into the housing (figure
38).
Remove J-23073-01.
Bearing support washer and retaining ring. Pull the
shift lever housing up far enough to compress the
lock plate washer.
Bearing support. Align the V in the support with
the V in the jacket.
Screws through the support and into the lock plate.
Screws to 6.8 N m (60 in. lbs.).
A lign the lower bearing adapter w ith the
notches in the jacket.
Adapter into the lower end of the jacket.
Lower bearing, bearing reinforcem ent and retaining
clip.
Align the retaining clip with the slots in the re
inforcement, jacket and adapter.
Centering spheres and anti-lash spring in the upper
shaft.
Lower shaft from the same side of the spheres that
the spring ends protrude.
Steering shaft assembly into the shift tube from the
upper end. Carefully guide the shaft through the
shift tube and bearing.
Ignition switch actuator rod through the shift lever
housing and insert it in the slot in the bearing sup
port.
Extend the rack downward from the bearing
housing.
Bearing housing over the steering shaft.
23.
24.
25.
26.
27.
Engage the rack over the end of the actuator

rod (figure 39).
With the release lever installed, hold the lock shoes
in the disengaged positions.
Bearing housing over the steering shaft until the
pivot pin holes line up.
Pivot pins.
Place the bearing in the full up position.
Tilt lever spring guide, spring and retainer.
With a suitable screwdriver, push the retainer
in and turn clockwise to engage it in the hous
ing.
Tilt lever opening shield.
Remove the tilt release lever.
Turn signal housing and retaining screws.
Tighten
Screws to 5 N-m (45 in. lbs.).

28. Tilt release lever and shift lever.
29. Ignition switch. Refer to Ignition Switch Replace
30. Tone alarm switch, if removed. Refer to Tone Alarm
Switch R eplacem ent in this section.
Remove the column from the vise.
Align the groove across the upper end of the pot
joint with the flat on the steering shaft. Install the pot
joint and intermediate shaft assembly to the upper
shaft (RV Model).
Figure 31Tilt Steering ColumnFloor Shift (RV and G Models)
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
R e ta in e r
N ut
L ock P late C over
R e ta in e r
L o ck P late
B e a rin g Preload S p rin g
Turn S ignal S cre w s
Tap S crew
A c tu a to r A rm
In n e r Race Seat
B e aring Race
S crew
R e ta in e r C lip
L o ck R e ta in e r S cre w
Ig n itio n L ock
H o u s in g C over
D im m e r S w itc h A c tu a to r
S h ie ld
Pin P reload S p rin g
P ivo t S w itc h
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
159.
160.
161.
162.
163.
164.
165.
166.
C ap
R e ta in e r
T ilt S p rin g
S p rin g G u id e
S crew
B e aring
L ock B o lt
L ock B o lt S p rin g
L o ck S hoe
L ock S hoe
S e c to r S h a ft
L o c k S h oe Pin
P ivot Pin
S hoe R elease S p rin g s
S p rin g
S hoe R elease Lever Pin
S hoe R elease Lever
L o w e r B e a rin g
R ack P reload S p rin g
A c tu a to r R ack
....
167.
168.
169.
170.
172.
173.
174.
175.
176.
177.
181.
182.
187.
188.
189.
190.
191.
199.
200.
201.
202.
203.
204.
205.
Ig n itio n S w itc h A c tu a to r
S phere S p rin g
C e n te rin g S p h e re s
S p rin g
L ow er S te e rin g S h a ft
H o u s in g S u p p o rt S cre w s
H o u s in g S u p p o rt
Pin
S h ift Lever G ate
D e te n t Plate S cre w
L o c k Plate
S cre w
S tu d
S w itc h
D im m e r S w itc h Rod
N ut
Pad
Key R elease Lever
Key R elease S p rin g
S h ro u d
L ow er B e aring
R e ta in e r
S cre w s
B-07368
Figure 32Tilt Steering ColumnFloor Shift (RV and V Models)

i
Install the clamp, bolt and nut. The clamp bolt
must pass through the shaft undercut.
Tighten
Nut to 60 N m (44 ft. lbs.).

33. Dash panel bracket and screws to the column.
0I
Install or Connect
Steering column. Refer to RV or G Model Steering
Column Replacement in this section.
Figure 33Bearing Housing Pivot Pins Removal
157. A c tu a to r S e c to r
166. A c tu a to r Rack
B-07411
Figure 37Lock Bolt and Rack Assemblies

Installation

P(32) MODELS
the lower left hand side of the bearing housing (tilt
columns) out the lower end of the shift lever housing
and under the dash seal.
Place the turn signal switch in position.
1. Turn signal switch mounting screws.
TURN SIGNAL SWITCH

REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
Tools Required:
J-22727 Electrical Terminal Remover
Cancelling cam and spring (standard columns).
Instrument panel trim plate (some models).
Turn signal switch wiring harness at the half-moon
connector.
Pry the wiring, harness protector out of the
column retaining slots.
M ark th e lo c a tio n o f e a ch w ire in th e
half-moon connector and then remove each
in d iv id u a l w ire from th e co nn ecto r. Use
J-22727 (figure 40). Insert the tool into the
lower end of the connector and push in until
the tool bottoms on the connector. Remove the
tool and then pul! the wire from the connector.
Turn signal lever screw and lever.
Hazard warning light knob. Press the knob inward
and unscrew.
On tilt columns.
Remove the PRNDL dial screws, dial and
indicator needle. Remove the cap and dial
illu m in a tio n bulb from the housing cover
(Automatic Transmission Model).
Unscrew and remove the tilt release lever.
Remove the turn signal housing cover, using a
pulley remover with reversed jaws.
Turn signal switch mounting screws.
Turn signal switch assembly from the column. Guide
the wiring harness through the opening in the shift
lever housing.
n- Install or Connect
Wrap the ends of the turn signal switch wires with
tape and then guide them through the opening at
4.
5.
6.
7.
Screws to 2.8 N m (25 in. lbs.

On tilt columns.
Align the openings in the turn signal switch
cover with the proper lever positions. Tap the
cover into place using a plastic hammer.
Install the tilt release lever.
In s ta ll th e P R N D L d ia l, p o in te r, d ia l
illu m in a tio n b u lb and c a p (A u to m a tic
Transmission Models).
Turn signal switch lever and screws.
Hazard warning knob.
Bend the wire retaining tabs, on each wire in the
wiring harness, enough to provide proper retention
of the wire in the half-moon connector.
Each wire in its marked location in the half-moon
connector. Push in until the square part of the clip is
flush with the bottom side of the connector.
Turn signal switch wiring harness.
W iring harness protector into the column retaining
slots.
Cancelling cam and spring (non-tilt column).

3B4-1.
9. Instrum ent panel trim plate (some models).
TILT STEERING COLUMN

REPLACEMENT
+- Remove or Disconnect (Figure 41)
4.
5.
6.
7.
8.

Transmission control linkage from the column shift
tube levers.
Nuts and washers that secure the flanged end of the
steering shaft to the flexible coupling.
Turn signal wiring harness.
On an automatic transm ission, disconnect the
single wire at the fuse block and unclip it from
the parking brake bracket.
Screws from the cover of the dash and toe panel
assembly.
Screws (211) and clam p (210) from the colum n
support bracket.
Steering column assembly.
L o w e r a n d th e n w ith d ra w th e c o lu m n
assembly. Rotate the column so the shift lever
clears the dash and toe panel assembly.

page 3B4-1.
Adjust the lower bearing preload. Refer to Steering
Column Lower Bearing A djustm ent in this section.
1. Plastic spacers onto the flexible coupling alignm ent
pins.
2. Lower end of the steering column through the toe
panel opening.
3. Low er ste e rin g s h a ft fla n g e onto th e fle x ib le
coupling.
4. Flange to coupling nuts.
A. (4.89 0.12 in ch ) E x c lu d in g FS3

B. (4.71 in ch ) w ith FS3
B-07417
Figure 42Coupling Assembly Measurement

Align the index slot in the steering column jacket
with the protrusion on the column support bracket.
5. Clamp (210) and screws (211) to the column support
bracket. Tighten bolts finger tight.
Push the column down until the steering shaft
flange bottoms on the plastic spacers on the flexible
coupling.
Tighten
Screws (211) to 25 N m (18 ft. lbs.).

Remove the plastic spacer from the alignm ent pins.
Measure
6.
7.
8.
9.
10.
Coupling assem bly dim ensions (figure 42).

Raise or lower steering column if necessary.
Cover and mounting screws to the dash and toe
panel assembly.
Turn signal switch wiring harness.
On an automatic transm ission, connect the
single wire to the fuse block and clip it to the
parking brack bracket.
Transmission control linkage.
TILT STEERING COLUMN BEARING

HOUSING REPLACEMENT
++
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Tools Required:
J-22635 Lock Shoe and Release Lever Pin
Remover and installer
J-21854-01 Pivot Pin Remover
J-5822 Steering Gear Shaft Main Bearing Cup
Remover
J-2619-01 Slide Hammer
Replacement in this section.
Turn signal switch. Refer to Turn Signal Switch
On column shift models, use a suitable size punch
to drive out the shift lever pivot and remove the shift
lever.
Install the tilt release lever and place the column in
the up position.
Retainer (230) and spring (232). Use a screwdriver
to turn the retainer until it aligns with the grooves in
the housing, then remove the retainer and spring.
Upper bearing nut (253).
Seat (254) and race (255).
Housing pivot pins (221). Use J-21854-01 (figure 45).
Bearing housing (219). Pull up on the tilt release
lever, this will disengage the shoes (224), and
remove the housing.
Upper and lower bearings (218, 220).
Remove the bearing races using J-5822 and
J-2619-01 (figure 46).
Tilt release lever.
11. Shoe release pivot pin (228). Use J-22635 or a

suitable punch (figure 47).
12. Spring (227) and lever (229).
13. Shoe kit assem bly (225).
If the upper steering shaft, lower steering shaft, or
centering spheres are being removed, proceed as
follows.
14. Steering shaft assembly through the upper end of
the column. If it is necessary to disassem ble the
shaft, proceed as follows:
Disconnect the shaft at the pot joint coupling
clam p and remove the lower steering shaft.
Turn the upper shaft 90 degrees to the lower
shaft and slide the upper shaft and centering
sphere from the lower shaft.
Rotate the centering spheres 90 degrees and
remove the centering spheres and spring from
the upper shaft.
If the bearing housing support is being replaced,
proceed as follows:
15. Screws (231).
16. Support (233).

page 3B4-1.
Lubricate the ID of the bearing housing support and
install the support and screws.
1. Steering shaft assembly.
Lubricate and assemble the centering spheres
and spring.
Install the spheres into the upper (short) shaft
and rotate 90 degrees.
Install the lower shaft 90 degrees to the upper
shaft and over the centering spheres. Slowly
straighten the shafts while compressing the
spring.
2. Steering shaft assem bly into the housing from the
upper end.
3. Lower steering column shaft to the intermediate
shaft (pot joint) assem bly (269).
Clamp (262) bolt (261) and nut (263). The bolt must
Tighten
5. Bearing housing (219) assembly.
Press the new upper and lower bearing races
into the bearing housing.
Lubricate and install the bearings into the
bearing races.
Place the shoe springs in position in the
hou sin g. In sta ll each shoe in place and
compress the spring in position. Once the
shoes are in place, drive in the shoe retaining
pin (226).
Install the shoe release lever (229), spring
(227) and pivot pin (228).
Install the tilt release lever.
Lubricate the shoes and release lever.
6. Bearing housing assem bly to the support (233).
225
216
247
261
B-07418
Figure 43Tilt Steering ColumnP(32) Model

215. H o u s in g C over
216. Turn S ig n a l
M o u n tin g S crew
217. Turn S ig n a l S w itc h
218. U p p e r B e aring
219. B e a rin g H o u s in g
220. L o w e r B earing
221. P ivot Pins
222. S hoe S p rin g
223. S p a ce r
224. S hoes
225. S hoe K it A s s e m b ly
226. S hoe R e ta in in g Pin
227. S p rin g
228. P ivot Pin
229.
230.
231.
232.
233.
234.
235.
236.
237.
238.
239.
240.
241.
Lever
R e ta in e r
S cre w s
S p rin g
S u p p o rt
Pin
D e te n t Plate
S crew
W a sh er
L o ck Plate
W a sh er
G ear S h ift Lever
S p rin g
242. G ear S h ift H o u s in g
243. G u id e
244. J a c k e t
245. B e aring
R e ta in e r C lip
246. R e in fo rc e m e n t
247. Dash Seal
248. Seal
249. S h ift Tube
250. A d a p te r
251. B e aring
252. N u t
253. N u t
254. Seat
255. Race
256. S h a ft
257.
258.
259.
260.
261.
262.
263.
264.
265.
266.
267.
268.
269.
S p rin g
S p h e re A s s e m b ly
L o w e r S h a ft
B o lt
C la m p
N ut
R e ta in e r
S p rin g
C o u p lin g A s s e m b ly
B e a rin g s
Seal
In te rm e d ia te
B-07369
Figure 44Tilt Steering ColumnP(32) Model

Hold the tilt release lever in the up position
u n til th e sh o e s have fu lly e n g a g e d th e
support.
Lubricate and install the bearing housing pivot
pins (221). Press the pins in flush with the
housing.
Place the housing in the up position.
7. Spring (232) and retainer (230). Push the retainer

into the housing about 5 mm (3/ie inch) and rotate
counterclockwise Vs turn.
Lubricate the upper bearing race (255), seat (254)
and nut (253).
8. Race (255), seat (254) and nut (253).
Remove the tilt release lever.
10. Shift lever and pivot pin. (Column Shift Models).
11. S te e rin g W h e e l. R e fe r to S te e rin g W h e e l
12. Tilt release lever.
L*
Inspect
E le c tric a l and m e c h a n ic a l fu n c tio n in g
steering column.
of the
B-07421
Figure 47Release Lever Pivot Pin Removal
Figure 46Bearing Race Removal
TILT STEERING COLUMN UNIT REPAIR

P(32) MODELS
Steering column assembly. Refer to Tilt Steering
Column R eplacem ent in this section.
Disassemble (Figures 43 and 44)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tool Required:
J-23072 Shift Tube Remover
Clamp the steering column in a vise.
Intermediate shaft assembly (270), with the univer
sal joint (pot joint), from the steering column shaft.
Bearing retainer clip (245) and reinforcement (246).
Bearing (251) and adapter (250).
Bearing housing assembly and steering shaft as
sembly. Refer to Tilt Steering Column Bearing
Housing R eplacem ent in this section.
If the shift tube index plate must be removed, re
move the two retaining screws and plate. (Column
Shift Models).
Shift tube retaining ring (237) and washer (238).
Neutral-safety or back-up lamp switch screws and
switch. Refer to SEC. 8B (CHASSIS ELECTRICAL)
in this manual.
Shift tube (249) assembly. Use J-23072. Do not
hammer or pull on the shift tube during removal (fig
ure 29).
Insert the hooked end of the tool into the notch
in the shift tube just below the shift lever hous
ing key. Pilot the sleeve over the threaded end
of the tool and into the upper end of the shift
tube. Force the shift tube out of the housing by
turning the nut onto the tool. If the shift tube is
not completely free when the nut is bottomed
on the threads, complete the removal by hand.
On column shift models, guide the lower shift
lever through the slotted opening in the col
umn to prevent dam age to the tube or column.
Lock plate (239) and washer (240). Tip the lock plate
downward towards the housing, then remove.
10. Shift lever housing.

Remove the shift lever spring by winding the spring
up with pliers (Column Shift Models).
11. Dash panel seal from the colum n jacket.
Assemble (Figures 43 and 44)
1.
2.
3.
4.
5.
6.
7.
Tools Required:
J-23073-01 Shift Tube Installer
faces.
Dash panes seal.
Press a new shift lever spring into the shift lever
housing (Column Shift Models).
Shift lever housing. Slide the housing over the up
per end of the column.
Washer (240) and lock plate (239).
Apply lithium grease to the lock plate and the
upper end of the shift tube.
Shift tube (249) and seal (248) into the lower end of
the column. Do not ham mer or force the shift tube.
Align the keyway in the shift tube with the key
in the shift lever housing and install the shift
tube using J-23073-01 (figure 38).
The shift lever housing key must bottom in the
shift tube slot.
Neutral-safety or back-up lamp switch and screws.
Refer to SEC. 8B (CHASSIS ELECTRICAL) in this
manual.
Washer (238) and retaining ring (237). Pull up on the
shift lever housing when installing the washer and
retaining ring.
Seat the retaining ring in both slots in the shift
tube.
Steering shaft assembly and bearing housing as
sembly. Refer to Tilt Steering Column Bearing
Housing R eplacem ent in this section.
-<- Install or Connect

Steering column assembly. Refer to Tilt Steering
Column R eplacem ent11 in this section.

P(42) MODELS
STANDARD STEERING COLUMN
REPLACEMENT
5. Screws (277) from the cover (278) and seal (279).

Slide the cover and seal up the column.
7. Turn signal wiring harness.
S te e rin g
W heel
2. Transmission control linkage from the column shift

tube levers (Column Shift Models).
On an automatic transm ission, disconnect the

conductor tube at the instrum ent panel.
3. U p p e r u n iv e rs a l jo in t p in c h b o lt fro m th e
interm ediate shaft. Mark the relationship of the
universal yoke to the steering shaft.
8. Bolts (275) and clamp (276) from the column support

bracket.
4. Nut (282), bolt (280) and clamp (281). Slide the

clamp down the column.
9. Bolt, nut and outer brace (283) from the column

support bracket (P200 + 300 (42) models).
10. Steering column assembly.
275.
276.
277.
278.
279.
280.
281.
282.
283.
B o lts
v
C la m p
S cre w s
C over
Seal
B o lt
C la m p
N ut
O u te r Brace
B-07422
Figure 48Steering Column InstallationP(42) Model

L o w e r a nd th e n w ith d ra w th e c o lu m n
assembly. Rotate the column so the shift lever
clears the dash and toe panel assembly.
El
* t l Install or Connect (Figure 48)

NOTICE: For steps 2, 3, 4 and 9 see N o tice on
page 3B4-1.
1. Adjust the lower bearing preload. Refer to Steering
Column Lower Bearing A djustm ent in this section.
2. Lower end of the steering colum n through the toe
panel opening.
Guide the steering shaft into the universal yoke,
lining up the marks made at removal.
Upper universal pinch bolt. The pinch bolt must
Tighten
this section.
Tighten
5. Seal (279), cover (278) and screws (277) to the dash
panel assembly.
6. Outer brace (283), bolt and nut to the colum n
support bracket (P200 + 300 (42) models).
Tighten
7. Transmission control linkage to the shift tube levers
(Column Shift Models).
8. Turn signal wiring harness.
On a s ta n d a rd c o lu m n w ith a u to m a tic
transm ission connect the conductor tube at
the instrum ent panel.
9. S te e rin g w h e e l.
R eplacem ent.
R e fe r to
S te e rin g
W heel
Align the seal (279) and cover (278) with the

floor and dash panel assembly.
Align the column support bracket protrusion

with the index slot in the steering column.
UPPER BEARING REPLACEMENT
3. Clamp (281), bolt (280) and nut (282). Position the

clam p as shown in figure 48.
Tighten
Clamp (276) and bolt (275).

2. Cancelling cam (286).
3. Upper bearing (289).
S te e rin g
W heel
316
285
278.
279.
285.
286.
287.
288.
289.
290.
291.
292.
293.
294.
295.
296.
297.
298.
299.
300.
301.
302.
303.
Seal
C over
H orn B lo w W ire
Turn S ig n a l S w itc h S cre w s
H azard C o n tro l S w itc h
U p p e r B e aring
C o n tro l S u p p o rt S w itc h
S crew
C o n tro l Lever
H o u s in g
W a sh e r
W a sh e r
S h ift Lever H o u s in g
P ivot Pin
Sleeve
S h ift Lever
Knob
S h a ft
B u s h in g
Seat
296
304.
305.
306.
307.
308.
309.
S h ift Tube
Ja c k e t
B o lts
W a sh e r
W a sh e r
N ut
310.
311.
312.
313.
314.
C la m p
B o lt
Spacer
Lever
A d ju s tin g Pin A n d B e a rin g A s s e m b ly
315.
316.
317.
318.
319.
320.
321.
S p rin g
C la m p
B o lt
W a sh er
N ut
Seal
C over
B-07423
Figure 49Standard Steering ColumnP(42) Model

304
A. 32 0.5 m m (1.26 0.02 inch)

B-07424
Figure 50Lower Bearing Adjustment
A. 8.4 to 9.1 m m (0.33 to 0.36 inch )

B. A d ju s tin g R ing
C. S h ift Lever
Install or Connect (Figure 49).

3B4-1.
B-07426
Figure 52Shift Tube AdjustmentAutomatic

Transmission
1. New upper bearing (289).

S te e rin g
W heel
2. Clamp (316), bolt (317), washer (318) and nut (319).

Maintain the clearance dimension shown in figure
50.
Tighten
LOWER BEARING REPLACEMENT

4-+ Remove or Disconnect (Figure 49)
1. Intermediate steering shaft. Refer to Intermediate
Shaft Replacement in this section.
2. Nut (319), washer (318), bolt (317) and clamp (316).

3. Intermediate shaft. Refer to Intermediate Shaft
STEERING COLUMN LOWER

BEARING ADJUSTMENT
3. Bearing assembly (315, 314).

page 3B4-1.
1. New adjusting ring and bearing assembly (314, 315).
1. Loosen clam p bolt (317).

2. Apply 222 N (50 lbs.) force to the steering wheel end
of the steering shaft.
3. Adjust the clam p to obtain a clearance of 32
0.5 mm (1.26 0.02 inch) (figure 51).
SHIFT TUBE ADJUSTMENT

3-SPEED MANUAL TRANSMISSION
1. Loosen the adjusting ring bolts (306).
2. Loosen the clam p bolt (317).
3. Rotate the adjusting ring to give a 0.13 mm (0.005
inch) end play between the adjusting ring and first
and reverse lever (figure 51).
&
Tighten
Adjusting ring bolt (306) to 8 N m (70 in. lbs.).
Clamp bolt (317) to 14 N m (10 ft. lbs.).
AUTOMATIC TRANSMISSION
1. Place the shift tube lever in N eutral or D rive.
2. Loosen the adjusting ring bolt (306).
3. Rotate the shift tube adjusting ring to obtain a 8.4 to
9.1 mm (0.33 to 0.36 inch) clearance between the
shift tube lever and adjusting ring (figure 52).
Figure 51Shift Tube Adjustment 3 Speed

Manual Transmission
Tighten
Adjusting ring bolt to 8 N m (70 in. lbs.).
STANDARD STEERING COLUMN UNIT REPAIR

P(42) MODELS
++
Steering colum n assembly. Refer to Standard
Steering Column Replacem ent (P42 Model) in this
section.
Disassemble (Figure 49)

Slide the steering shaft assembly from the lower
end of the steering column.
1. Lower bearing bolt (317), washer (318), nut (319),
clam p (316) and spring (315).
2. Back-up lamp switch.
3. Pivot pin (297) and shift lever (299).
5. Conrol lever screw (291) and lever (292).
6. Column wiring harness cover.
7. Turn signal switch screws (287).
8. Housing (293). Rotate the housing counterclock
wise.
The housing and switch cannot be completely
removed from the column until the shift lever
housing is removed.
9. Washer assembly (294, 295) and shift lever housing
(296) (or extension housing) from the column.
Separate the turn signal switch, switch control sup
port assembly, turn signal housing and shift lever
housing (or housing extension) assemblies.
10. Upper bearing (289). Press the bearing out of the
switch contact support (290).
11. Bushing (302) and seat (303).
12. Bolts (306), washers (307, 308) and adjusting ring
clam p (310).
13. Adjusting ring and bearing (314) assembly.
Press the bearing out of the adjusing ring.
14. First-reverse shift lever and spacer (3-Speed Col
umn).
15. Selector plate clam ping screws (Autom atic Col
umns).
Place the column upright on the floor, supporting it
with two pieces of wood. Place a block of wood on
the upper end of the shift tube. Press down on the
shift lever with foot while tapping on the wood block
to withdraw the tube from the column jacket.
NOTICE: In some tolerance stack-up cases it
may be necessary to use a press. Be careful not
to damage the tube or jacket.
16. Seal (320) and cover (321).
17. Cover (279), seal (278) and clam p from steering col
umn jacket (305).
Assemble (Figure 49)

faces.
1. Clamp, seal (278) and cover (279) over the end of
the jacket (305).
Apply lithium grease to all bearing surfaces on the
shift tube.
2. Seal (320) onto the shift tube and place the shift
tube in the jacket.
Temporarily install the spacer, first-reverse shift lever
and lower adjusting ring. Place a block of wood on
top of the adjusting ring and tap until the shift tube
bottoms. Remove the adjusting ring, shift lever and
spacer (3-Speed Columns).
Align the three holes in the selector plate with the
three holes in the jacket. Position the clam ping ring
and install the three screws. The shift tube spring
retainer must bottom against the jacket stops (Auto
m atic Columns).
Lubricate and install the spacer and first-reverse
shift lever. The tang of the lever is toward the top of
the column (3-Speed Column).
3. Bearing in the adjusting ring (314).
4. Adjusting ring and bearing (314) assembly, clamp
(310), washers (308, 307) and bolts (306).
5. Seat (303) and bushing (302) to the upper end of the
housing.
T hread the tu rn sign al sw itch w irin g harness
through the switch and lever (or extension) housing.
Lubricate the inner diam eter of the shift housing.
6. Shift lever (or extension) housing onto the upper
end of the column.
7. Washer assembly (295, 294).
8. Upper bearing into the switch contact support.
9. Turn signal switch housing (293), contact support,
bearing, switch and switch screws. Tighten screws
to 2.8 N-m (25 in. lbs.).
10. W iring harness cover and back-up lamp switch.
11. Control lever (292) and the gear shift lever (299).
Adjust
Shift tube. Refer to Shift Tube A djustm ent in
this section.
12. Spring (315), clamp (316), bolt (317), washer (318)
and nut (319). Tighten the bolt finger tight.
Slide the steering shaft assem bly up through the
column assembly.
Steering colum n assembly. Refer to Standard
INTERMEDIATE SHAFT UNIT REPAIR P(42) MODELS
Figure 53Intermediate ShaftP(42) Model

Intermediate shaft. Refer to Intermediate Shaft Replacem ent in this section.

If the upper and lower half of the intermediate shaft
is to be replaced, preceed as follows:
Place the intermediate shaft (320) on a bench and
straighten the tangs on the dust cap (329). Separate
the upper and lower portions of the shaft assembly.
1. Dust cap (329) and dust seal (328).
If the trunnion assembles are to be replaced, pro
ceed as follows:
2. Bearing cups (325).
Support the yoke on a bench vise and drive
out one bearing cup by tapping on the oppo
site bearing cup. Use a soft drift and hammer.
Support the other side of the yoke and drive
out the remaining bearing cups, as described
in the previous step.
3. Trunnion (326) from the yokes (324, 327).
4. Trunnion (326) from the yokes, (331, 330).

If the yoke trunnions were removed, assemble as
follows:
1. Trunnion (326) into the yokes (331, 330).
2. Trunnion (326) into the yokes (327, 321).
3. Bearing cups (325) into the yokes.
Reassemble the intermediate shaft assem bly as fol
lows:
4. Dust cap (329) and dust seal (328) over the shaft of
the lower yoke (330) assembly.
Align the arrow on the lower yoke assembly shaft
with the arrow on the upper yoke assembly tube and
push the two assemblies together.
Push the dust seal (328) and dust cap (329) into
position on the lower end of the upper yoke assem
bly and bend the tangs of the dust cap down against
the yoke tube.
++
Install or Connect
Intermediate shaft. Refer to Intermediate Shaft Re
SPECIFICATIONS
Turn Signal Switch Attaching S c re w s ..................................................................
Ignition Switch Attaching S c re w s .........................................................................
Dimmer Switch Attaching S cre w s.........................................................................
Steering Wheel N u t .................................................................................................
Flexible Coupling Clamp B o lt ...............................................................................
Flexible Coupling To Flange Bolt N u ts ................................................................
Steering Gear To Frame Bolts (C, K And G M o d e ls )........................................
Steering Gear To Frame Bolts P300 (32, 42) F S 3 ............................................
Steering Gear To Frame Bolts P200 & 300(42) Excluding F S 3......................
Upper Intermediate Shaft Pinch Bolt (G M odel).................................................
Lower Intermediate Shaft Pinch Bolt (G M odel).................................................
Intermediate Shaft Pinch Bolt P300 (42) FS3.....................................................
Intermediate Shaft Pinch Bolt P200 & 300(42) Excluding F S 3 ......................
Steering Column Support Bracket Screws (C, K And G M o d e ls )..................
Steering Column Support Bracket Clamp Nuts (P M odels).............................
Steering Column Shaft To Intermediate Shaft (Pot Joint) A s se m b ly.............
N-m
4.0
4.0
4.0
40
42
27
102
108
95
47
62
108
102
30
25
60
Ft. Lbs.
30
31
20
75
80
70
35
46
80
75
22
18
44
In. Lbs.
35
35
35
SPECIAL TOOLS
J-1859-03
J -
2 6 1 9 -
0 1
J-5822
J-22727
J-23072
J-23073-01
J-21854-01
J-23653-A
J-22635
1.
2.
3.
4.
5.
C ra n k s h a ft F ro n t C ove r O il Seal P u lle r

S lid e H a m m e r
W o rm B e aring A d ju s te r C u p P u lle r
P ivo t Pin R em ove r
L ock S hoe and R elease Lever Pin R em ove r and In s ta lle r
6.
7.
8.
9.
T erm in al R em ove r
S h ift Tube R em ove r
S h ift, Tube In s tlle r
L o c k P late C o m p re s s o r
F-02652
3C-1
SECTION 3C
FRONT SUSPENSION
manual as indicated at appropriate locations by the term inology NOTICE: Refer to Notice on page 3C-1 of this sec
tio n .
NOTICE: All front suspension fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser
o f these parts.
CONTENTS
SUBJECT
PAGE
General Description....................................................................................................................................................... 3C- 2

Diagnosis of Front S uspension.................................................................................................................................. 3C- 2
Shock Absorber Bench T e st.................................................................................................................................... 3C- 3
Diagnosis of Wheel Bearings...................................................................................................................................... 3C- 3
On-Vehicle Service: Independent Front Suspension............................................................................................... 3C- 8
Shock Absorber......................................................................................................................................................... 3C- 8
Stabilizer B a r ............................................................................................................................................................. 3C- 8
Wheel Hub/Rotor A ssem bly.................................................................................................................................... 3C- 8
Wheel Bearing Adjustm ent...................................................................................................................................... 3C-13
Wheel Hub B o lt ......................................................................................................................................................... 3C-15
Steering K nuckle....................................................................................................................................................... 3C-15
Coil S p rin g ................................................................................................................................................................. 3C-17
Lower Ball J o in t......................................................................................................................................................... 3C-17
Upper Ball J o in t......................................................................................................................................................... 3C-19
Lower Control Arm Pivot Shaft and B u sh in g s..................................................................................................... 3C-20
Upper Control Arm Pivot Shaft and B u sh in g s ..................................................................................................... 3C-23
Lower Control Arm ...................................................................................................................................................3C-24
Upper Control Arm ..................................................................................................................................................... 3C-25
Suspension U nit......................................................................................................................................................... 3C-26
On-Vehicle Service: I-Beam (RPO FS3) Front Suspension.....................................................................................3C-28
Shock Absorber........................... ..............................................................................................................................3C-28
Stabilizer B a r ............................................................................................................................................................. 3C-30
Wheel Hub/Rotor A ssem bly.....................................................................................................................................3C-31
Wheel Bearing A djustm ent...................................................................................................................................... 3C-32
Wheel Hub B o lt ......................................................................................................................................................... 3C-33
Steering Arm, Knuckle and Spindle........................................................................................................................ 3C-33
Front A xle ................................................................................................................................................................... 3C-34
Leaf Springs............................................................................................................................................................... 3C-34
On-Vehicle Service: Four Wheel Drive Front Suspension....................................................................................... 3C-36
Shock Absorber......................................................................................................................................................... 3C-36
Stabilizer B a r ............................................................................................................................................................. 3C-36
Wheel Hub/Rotor A ssem bly.................................................................................................................................... 3C-36
Bearing Adjustm ent...................................................................................................................................................3C-37
Wheel Hub B o lt .........................................................................................................................................................3C-41
S p in d le ....................................................................................................................................................................... 3C-41
Steering Knuckle and A r m ..................................................................................................... ................................ 3C-45
Ball Joints (V10/1500 and 20/2500 Models O n ly)................................................................................................. 3C-48
Leaf Spring And B u s h in g s ...................................................................................................................................... 3C-49
S p e c ific a tio n s............................................................................................................................................................... 3C-51
End P la y ..................................................................................................................................................................... 3C-51
Fastener Torque......................................................................................................................................................... 3C-51
Special T o o ls ................................................................................................................................................................. 3C-53
3C-2 FRONT SUSPENSION
GENERAL DESCRIPTION
An independent suspension is standard on the R-G-P
model vehicles. This suspension features unequal length
control arms (the lower control arm is the load carrying
member), coil springs and shock absorbers to reduce vi
bration and shock load, plus a stabilizer bar to control
sway or roll. Air cylinders inside coil springs are available
to minimize crash through on large road bumps. A
special heavy duty front suspension is available on P

model vehicles. This suspension (RPO FS3), centered
around a solid I-beam axle, includes leaf springs, shock
absorbers, and a stabilizer bar.
The V model (four wheel drive) suspension includes
leaf springs, shock absorbers, and a stabilizer bar.
DIAGNOSIS OF FRONT SUSPENSION

PROBLEM
Hard Steering
POSSIBLE CAUSE
1. Ball joints and steering linkage need lu
brication.
2. Low or uneven front tire pressure.
3. Incorrect front wheel alignm ent (manual
steering).
Poor Directional
Stability

brication.
2. Low or uneven front or rear tire pressure.
3.
4.
5.
6.
7.
Front Wheel Shimmy

(Smooth Road Shake)
Vehicle Pulls To One

Side (No Braking
Action)
Noise In The Front

End
Loose wheel bearings.

Incorrect front wheel alignm ent (caster).
Broken springs.
M alfunctioning shock absorber.
Broken stabilizer bar or a missing link.
1. Tire and wheel are out of balance or out

of round.
2. Worn or loose wheel bearings.
3. Worn ball joints.
4. M alfunctioning shock absorber.
1. Low or uneven tire pressure.
2. Front or rear brakes dragging.
3. Broken or sagging front spring.
4. Incorrect front wheel alignm ent (cam
ber).
brication.
2. Loose shock absorber or worn bushings.
1. Lubricate the ball joints and linkage.

2. Inflate tires to the recommended pres
sure.
3. Check and align the front suspension.
1. Lubricate the ball joints and linkage.

2. Inflate tires to the recommended pres
sure.
3. Adjust the wheel bearings.
5. Replace the springs.
6. Check and replace the shock absorber.
7. Replace the stabilizer bar or link.
1. Balance the tires, check run-out.
3. Replace the ball joints.
4. Check and replace the shock absorber.
1. Inflate the tires to the recommended
pressure.
2. Adjust the brakes.
6. Loose wheel nuts.

7. Spring is improperly positioned.
8. Loose suspension bolts.
1. Lubricate at the recommended inter

vals.
2. Tighten the bolts or replace the shock
absorber.
3. Replace the bushings.
4. Adjust or replace the wheel bearings.
5. Tighten all the stabilizer bar attach
ments.
6. Tighten the wheel nuts.
7. Reposition the spring.
8. Tighten to specifications or replace.
1.
2.
3.
4.
1.
2.
3.
4.
3. Worn control arm bushings.

4. Worn or loose wheel bearings.
5. Loose stabilizer bar.
Wheel Tramp
CORRECTION
Tire and the wheel are out of balance.

Tire and the wheel are out of round.
Blister or bump on the tire.
Improper shock absorber action.
Balance
Replace
Replace
Replace
the
the
the
the
wheels.
tire.
tire.
shock absorber.
FRONT SUSPENSION 3C-3
DIAGNOSIS OF FRONT SUSPENSION (CONT.)

E xcessive o r U neven
T ire W ear
C upped T ires
1. Inflate the tire to the recom m ended

pressure.
2. Adjust toe-in setting.
3. Balance the wheels.
4. Follow proper driving techniques.
5. Do not exceed the maximum recom
mended payload rating.
1. Underinflated or overinflated tires.

2.
3.
4.
5.
S cu ffe d Tires
CORRECTION
POSSIBLE CAUSE
PROBLEM
Im proper toe-in.
W heels are out of balance.
Hard driving.
Overloading the vehicle.
4. Suspension arm is bent or twisted.
1. Adjust toe-in setting.

2. Follow proper driving techniques.
3. Inflate the tires to the recommended
pressure.
4. Replace the suspension arm.
1. Front shock absorbers are defective.

2. Worn ball joints.
3. Wheel bearings are incorrectly adjusted
or worn.
4. Wheel and tire is out of balance.
5. Excessive tire or wheel runout.
1. Replace the shock absorbers.

2. Replace the ball joints.
3. Adjust or replace the wheel bearings
(also replace the races).
4. Balance the wheel and tire.
5. Check and compensate for runout.
1. Toe-in is incorrect.
2. Excessive speed on turns.
3. Tires are improperly inflated.
SHOCK ABSORBER BENCH TEST

SPIRAL GROOVE SHOCK ABSORBERS
1. Purge the air from the pressure chamber.
Extend the shock verticallytop end up.
Turn the sh o ck o ver and c o lla p s e it
verticallytop end down.
Repeat the above step five times.
2. Place the shock absorber in a vise with the jaws
clamped onto the shocks bottom mount.
Shock absorber should be positioned vertically
in the visetop end up.
Do not clamp the vise Jaws on the shocks
reservoir tube.
3. Pump the shock absorber at various rates of speed
and observe the rebound force.
Rebound force is normally stronger than the
compression force (approximately two to one).
Rebound force should be smooth and constant
for each stroke rate.
4. Compare with a good shock absorber.
5. If one of the following are observed, replace the shock
absorber.
A skip or lag at reversal near mid-stroke.
A seize (except at the extreme ends of travel.
A noise (grunt or squeal) after completing one
full stroke in both directions.
A clicking noise at fast reversal.
NON-SPIRAL GROOVE SHOCK ABSORBERS

Purging air from non-spiral groove shock absorbers is
not necessary. The shock absorbers have a gas filled
cell in their reservoirs (as opposed to the air filled cell
in the spiral groove shock absorber reservoirs).
1. Place the shock absorber in a vise with the jaws
clamped on the shock absorbers top mount.
Shock absorber should be held vertically in the
vise with its bottom end up.
Do not clamp the vise jaws on the shocks
reservoir tube.I
2. Pump the shock absorber at various rates of speed
and observe the rebound force.
Rebound force is normally stronger than the
compression force (approximately two to one).
Rebound force should be smooth and constant
for each stroke rate.
3. Compare with a good shock absorber.
4. If one of the following are observed, replace the shock
absorber.
A skip or lag at reversal near mid-stroke.
A seize (except at the extreme ends of travel).
A noise (grunt or squeal) after completing one
full stroke in both directions.
A clicking noise at fast reversal.
DIAGNOSIS OF WHEEL BEARINGS

When diagnosing bearing condition, keep in mind the
general condition of all parts during disassem bly and
inspection. Use Figures 1, 2, 3 and 4 to classify the failure, and follow the recommended repair procedures.
ABRASIVE ROLLER WEAR
ABRASIVE STEP WEAR
Pattern on race s and ro lle rs ca u se d by fin e

abrasives.
C lean all p a rts and h o u s in g s , c h e c k se a ls and
b e a rin g s a nd re p la c e if le a k in g , ro u g h o r
noisy.
Pattern on ro lle r e n d s c a u s e d by fin e a bra

sives.
C lean all p a rts and h o u s in g s , c h e c k s e a ls and
b e a rin g s and re p la c e if le a k in g , ro u g h o r
noisy.
GALLING
ETCHING
M eta l sm e a rs on ro lle r e n d s due to o verheat,

lu b ric a n t fa ilu re o r o verlo a d.
R ep lace b e a rin g , c h e c k se a ls and c h e c k fo r
p ro p e r lu b ric a tio n .
B e aring s u rfa c e s a p p e a r gray o r g ra y is h b la c k

in c o lo r w ith related e tc h in g aw ay o f m a te ria l
u s u a lly at ro lle r s p a c in g .
R ep lace b e a rin g s, c h e c k s e a ls and c h e c k fo r
B-09194
Figure 1Diagnosis of Front Wheel Bearings
BENT CAGE
BENT CAGE
C age d a m a g e d due to im p ro p e r h a n d lin g o r
C age d a m a g e d d u e to im p ro p e r h a n d lin g o r
to o l usage.
R ep lace b e a rin g.
to o l usage.
R ep lace b e a rin g .
CAGE WEAR
INDENTATIONS
W ear a ro u n d o u ts id e d ia m e te r o f cage and

ro lle r p o c k e ts ca use d by a b ra sive m a te ria l
and in e ffic ie n t lu b ric a tio n .
C lean related p arts and h o u s in g s .
C h e c k se a ls and rep la ce b e a rin g s.
S u rfa c e d e p r e s s io n s o n ra c e a n d r o lle r s
c a u se d by hard p a rtic le s o f fo re ig n m a te ria l.
C lean all p a rts and h o u s in g s . C h e c k s e a ls and
rep la ce b e a rin g s if rou gh o r noisy.
B-09195
FRETTAGE
SMEARS
C o rro s io n se t up by sm a ll relative m o ve m e n t
o f p a rts w ith no lu b ric a tio n .
R eplace b e a rin g . C lean related parts. C h e ck
se als and c h e c k fo r p ro p e r lu b ric a tio n .
S m e a rin g o f m eta l d ue to s lip p a g e . S lip p a g e

c a n be c a u s e d by p o o r f it s , lu b r ic a tio n ,
o v e rh e a tin g , o v e rlo a d s o r h a n d lin g dam age.
R e p la ce b e a rin g s , c le a n re la te d p a rts and
c h e c k fo r p ro p e r fit and lu b ric a tio n .
STAIN DISCOLORATION
HEAT DISCOLORATION
D is c o lo ra tio n can range fro m lig h t brow n to

b la ck ca u se d by in c o rre c t lu b ric a n t o r m o is
ture.
Re-use b e a rin g s if s ta in s can be rem oved by
lig h t p o lis h in g o r if no e vid e n ce o f o ve rh e a t
ing is o bse rve d .
H eat d is c o lo ra tio n can range fro m fa in t y e l

low to d ark b lu e re s u ltin g fro m o ve rlo a d o r in c o rre c t lu b ric a n t.
E xce ssive heat can ca u s e s o fte n in g o f races
o r rollers. To c h e c k fo r lo s s o f te m p e r on
C h e ck se a ls and related p a rts fo r dam age.
races o r ro lle rs a s im p le file te s t m ay be

m ade. A file d ra w n o ver a te m p e re d part w ill
grab and c u t m e ta l, w he re a s, a file d ra w n over
a hard part w ill g lid e re a d ily w ith no m eta l
c u ttin g .
R eplace b e a rin g s if o ver h e a tin g d am ag e is
in d ic a te d . C h e c k se a ls and o th e r parts.
B-00531
MISALIGNMENT
CRACKED INNER RACE
O u te r race m is a lig n m e n t d ue to fo re ig n o b
Race cra c k e d d u e to im p ro p e r fit, c o c k in g , o r

p o o r b e a rin g seats.
R eplace b e a rin g and c o rre c t b ea rin g seats.
je c t.
C lean related p a rts and rep la ce b e a rin g. M ake
su re races are p ro p e rly seated.
BRINELLING
FATIGUE SPALLING
F la k in g o f su rfa c e m e ta l re s u ltin g fro m
tig u e .
R ep lace b ea rin g, cle a n all related parts.
fa
S u rfa c e in d e n ta tio n s in racew ay ca u s e d by

ro lle rs e ith e r u n d e r im p a c t lo a d in g o r v ib ra
tio n w h ile th e b e a rin g is n o t ro ta tin g .
R eplace b e a rin g if rou gh o r noisy.
B-09860
ON-VEHICLE SERVICE:
INDEPENDENT FRONT SUSPENSION
SHOCK ABSORBER
Remove or Disconnect (Figures 5, 6, 7, 8, and
9)
Raise the vehicle on a hoist.
1. Shock absorber (20) from the lower control arm.
Nuts (23), washers (22) and bolts (21) (Figure 9).
2. Shock absorber (20) from the frame.
Nuts (16), washers (17), and bolts (21) (Figure 9).
If
Inspect
Shock absorbers for damage and leaking.
Test the shock absorbers. Refer to Shock Absorber
Bench Test in this section.
El
* t i Install or Connect (Figures 5 through 9)
NOTICE: Refer to
this section.
N o tice on page 3 C - 1 of
2. Stabilizer bar (59) to the vehicle.

Position the stabilizer bar and attach the clamps
(52), bolts (54), washers (55, 57) and nuts (58).
Clamps (42), bolts (43), washers (39, 41) and nuts
(38).
R and P models.
Nuts (38, 58) to 33 N m (24 ft. lbs.).
G models.
Nut (38) to 29 N-m (21 ft. lbs.).
Bolt (54) to 33 N m (24 ft. lbs.).
3. Wheel and tire assembly. Lower the vehicle.
NOTICE: Refer to N o tice on page 3 C - 1 of

this section.
1. Shock absorber (20) onto the vehicle.
Bolts (21), washers (17, 22), and nuts (16, 23)
(figure 9).
Tighten
R models.
Nut (16) to 190 N m (140 ft. lbs.).
Bolt (21) to 80 N m (59 ft. lbs.).
G models.
Bolts (21) to 103 N-m (80 ft. lbs.).
P models.
Nut (16) to 190 N-m (140 ft. lbs.).
Nut (23) to 80 N-m (59 ft. lbs.).
2. Lower the vehicle.
STABILIZER BAR
Remove or Disconnect (Figures 5 through 8
and 10)
Raise the vehicle and support with suitable safety
stands. Remove the wheel and tire assembly.
1. Stabilizer bar (59) from the frame.
Bolts (54), nuts (58), washers (55, 57) and clamps
(52).
2. Stabilizer bar (59) from the lower control arm (36).
Bolts (43), nuts (38), washers (39, 41) and clamps
(42).
Stabilizer bar (59) drops down remove the
bushings (40, 53).
I*
Inspect
Rubber bushings (40, 53) for excessive wear,
a g in g , o r o th e r d a m a g e . R e p la c e as
necessary.
* i l Install or Connect (Figures 5 through 10)

1. Bushings (40, 53) to the stabilizer bar (59).
Slit on the insulator faces forward.
Use rubber lubricant to ease the installation.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
B o lt
W a sh e r
N ut
B o lt
W a sh e r
B o lt
W a sh er
B ra cke t
N ut
R ivet
F ittin g
U p p e r B all J o in t
N ut
C o tte r Pin
N ut
W a sh e r
S h im Pack
S pacer
S h o c k A b s o rb e r
B o lt
W a sh e r
N ut
N ut
R e ta in e r
B u s h in g
N ut
U p p e r C o n tro l A rm
P ivo t S h a ft
Bum per
C o il S p rin g
Bum per
C o tte r Pin
N ut
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
L o w e r C o n tro l A rm
L o w e r Ball J o in t
N ut
W asher
B u s h in g
W asher
B ra c k e t
B o lt
U -B o lt
R ivet
B u s h in g
B ra c k e t
W asher
N ut
P ivo t S h a ft
R ivet
B ra cke t
B u s h in g
B o lt
W asher
B ra cke t
W asher
N ut
S ta b iliz e r Bar
B o lt
W a sh e r
W a sh e r
N ut
B race
B o lt
W asher
N ut
Seal
A ir C y lin d e r
B-07469
Figure 5R-G-P Models Front Suspension
67
66
64
63
B-07466
Figure 6R Model Front Suspension Components
Figure 7G Model Front Suspension Components
Figure 8P Model Front Suspension Components

WHEEL HUB/ROTOR ASSEMBLY
Use J-8457 to drive the outer bearing outer race

(75) into position (figure 12).
Turn over the hub/rotor, remove J-9746-02, and
drive in the inner bearing outer race (82) with
J-8449.
R em ove o r D is c o n n e c t (F ig u re s 5 th ro u g h 8,
and 11)
Raise the vehicle and support it with suitable safety
1. Caliper. Refer to BRAKES (SEC. 5).
NOTICE: Support the caliper with a piece of
wire to prevent damage to the brake line.
2. Wheel Hub/Rotor (81)
Dust cap (79).
Cotter pin (80), nut (78), and washer (77).
Pull the hub/rotor free, making sure the outer
wheel bearing (76) comes free of the hub/rotor.
Do not damage the steering knuckle (70) spindle
threads.
3. Inner wheel bearing (73).
Pry out the seal (72).
4. Races (75, 82).
Drive out each race using a brass drift inserted
behind the race in notches in the hub.
)QI
Clean
1. Grease from the hub/rotor (81) and steering knuckle

spindle.
Remove grease from inside the hub.
2. Grease from the wheel bearings (73, 76) and races (72,
75).
Use clean solvent and a small brush (no loose
bristles).
Do not spin the wheel bearings with compressed
ai'r to dry themthe wheel bearings may be
damaged.
Inspect
1. Wheel bearings (73, 76) and their races (72, 75) for
damage or wear.
Refer to Diagnosis of Wheel Bearings, in this
section.
If either a bearing or its race is damaged or worn,
replace both.
2. Hub/rotor for damage.
Out-of-round or scored conditions.
Pitting or cracks.
-+ Install or Connect (Figures 5 through 8, 11 and

12)
Tools Required:
J-8092 Driver Handle
J-8457 Wheel Bearing Race Installer
J-8849 Wheel Bearing Race Installer
J-9746-02 Hub/Rotor Support
NOTICE: Start the races squarely inside the
h u b /ro to r to avoid d isto rtio n and p o ssible
cracking.
1. Races (72, 75) into the hub/rotor (81).
Place the hub/rotor on J-9746-02 and rest this
assembly on press bars.
Im portant
Use an approved high-tem perature front wheel

bearing grease to lubricate the bearings. Refer to
Do not mix different greases as mixing may change
th e g re a s e s p ro p e rtie s r e s u ltin g in p o o r
performance.
2. Apply a thin film of grease to the steering knuckle
spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each
wheel bearing dust cap (79).
NOTICE: Failure to com pletely pack the wheel
bearing (cones, rollers, and cage) with grease
will result in premature wheel bearing damage
and/or wear.
4. Fill each wheel bearing (cone and roller assembly)
full of grease.
Use a cone-type grease machine that forces
grease into the bearing.
If a cone-type grease machine is not available,
pack the wheel bearing by hand.
When packing the wheel bearing by hand, work
the grease into the bearings between the rollers,
cones, and the cage.
5. Inner wheel bearing (73) into the hub/rotor (81).
Put an additional quantity of grease outboard of
this bearing.
6. New seal (72).
Use a flat plate or block to install the seal to
insure it is flush with the hub/rotor flange.
Lubricate the seal lip with a thin layer of grease.
7. Hub/rotor (81).
Do not damage the steering knuckle spindle
threads.
8. Outer wheel bearing (76).
Slide it over the spindle until the wheel bearing
(76) fully seats against the hub/rotor outer race
(75).
this section.
9. Washer (77), nut (78), and cotter pin (80).
Do not place the cotter pin through the hole in
the spin dle u n til the w heel b ea rin gs are
adjusted.
Tighten
Nut (78) to 16 N m (12 ft. lbs.) while turning the
hub/rotor assembly in either direction.
10. Put an additional quantity of grease outboard of the
wheel bearing (76).
Refer to Wheel Bearing Adjustment, in this
section.
21
B. G S e rie s
16. N u t
17. W a sh e r
20. S h o c k A b s o rb e r
21. B o lt
22. W a sh e r
23. N u t
B-07473
Figure 9Shock Absorber Attachment Points

12. Dust cap (79) on the hub/rotor (81).
13. Caliper. Refer to BRAKES (SEC. 5).
14. Tire and wheel assembly and lower the vehicle.
be a slip fit on the spindle and the inside diameter of

the wheel bearing must be lubricated to ensure the
bearings will creep. The spindle nut (78) must have
a free-running fit on the spindle threads.
WHEEL BEARING ADJUSTMENT

| j | Important
The proper functioning of the front suspension
cannot be m aintain ed unless the fro n t w heel
bearings are correctly adjusted. The bearings must
38.
39.
40.
41.
42.
43.
52.
53.
54.
55.
57.
58.
59.
N O T IC E : N e v e r p r e lo a d th e fr o n t w h e e l
bearings. Damage can result by the steady
thrust on the roller ends which comes from
preloading.
N ut
W a sh e r
B u s h in g
W a sh e r
C la m p
B o lt
C la m p
B u s h in g
B o lt
W a sh e r
W a sh er
N ut
S ta b iliz e r Bar
B-07475
Figure 10Stabilizer Bar Attachment Points
78
70.
71.
72.
73.
74.
75.
S h ie ld
Seal
In n e r W h e e l B e a rin g
W h e e l H u b B o lt
O u te r Race
76.
77.
78.
79.
80.
81.
O u te r W h e e l B e aring
W a sh er
N ut
D u st C ap
C o tte r Pin
W h e e l H u b /R o to r
79
82.
83.
84.
85.
B-07470
Figure 11Steering Knuckle and Hub Components

A djust
stands under the lower control arms.
1. Remove the dust cap (79) from the hub/rotor (81).
2. Remove the cotter pin (80).
Tighten
Nut (78) to 16 N-m (12 ft. lbs.) while rotating the

wheel and tire assembly (this will seat the bearings).
3. Back off the nut (78) to the just loose position.
4. Hand tighten the nut (78).
5. Back off the nut (78) until the hole in the spindle
lines up with a slot on the nut.
Do not back off more than 1/2 of a flat.
6. New cotter pin (80).
Make sure the bent ends do not interfere with the
dust cap (79).
Measure
Endplay in the hub/rotor assem bly (81).
It should measure between 0.03 mm (0.0012 inches)
and 0.13 mm (0.005 inches) when properly adjusted.
7. Install the dust cap (79) on the hub/rotor (81).
8. Install the wheel and tire assembly if removed and
lower the vehicle.
A. W ashers
B. N ut
81. H u b /R o to r
Figure 14Installing the Hub Bolts

Remove the nut and washers.
2. Hub/rotor to the vehicle.
Refer to Wheel Hub, Bearing and Race, in this
section.
STEERING KNUCKLE
Remove or Disconnect (Figures 5 through 8,
15 and 16)
A. Press Bars
B-07729
Figure 13Removing the Hub Bolts
Tools Required:
J-23742 Ball Joint Separator
Important
It is recommended that the vehicle be raised and
WHEEL HUB BOLT

!<--[ Remove or Disconnect (Figures 5 through 8,
and 13)
Tools Required:
1. Hub/rotor from the vehicle.
Refer to Wheel Hub, Bearing and Race in this
section.
NOTICE: Place J-9746-02 between the press
bars and the hub/rotor to protect the rotor
surfaces.
2. Wheel hub bolts (74) with a press.
Support the hub/rotor (81) using J-9746-02 and
press bars (figure 13).
Do not damage the wheel mounting surface on
the hub/rotor flange.
Install or Connect (Figures 5 through 8, and

14)
NOTICE: Refer to the N otice on page 3 C - 1
o f this section.
1. Wheel hub bolts (74) into the hub/rotor (81).
Place four washers onto the bolt, then fasten a
nut onto the bolt until the nut bottoms on the
washers (figure 14).
Tighten the nut until the bolt fully seats into the
hub/rotor (81).
Figure 15Disconnecting the Upper Ball Joint

Steering knuckle (70) from the lower ball joint (37).
Use J-23742 to break the lower ball joint free
from the steering knuckle (figure 16).
Lift the steering knuckle off the lower ball joint.
Inspect
I?
1. Tapered holes in the steering knuckle that attach to
the ball joints and the tie rod end.

Remove any dirt.
If any tapered hole is out of round, deformed, or
damaged in any way, replace the steering
knuckle (70).
2 . Spindle for wear or damage.
The steering knuckle (70) must be replaced if the
spindle is damaged or worn.
N O TIC E: For step s 3 a n d 8, re fe r to the
N o tice on page 3 C - 1 of this section.
1. Steering knuckle (70) to the lower ball joint (37).

Press the steering knuckle onto the lower ball
joint (37) until it is fully seated.
2. Steering knuckle (70) to the upper ball joint (13).
Lower the upper control arm (28) to seat the
upper ball joint (13) into the steering knuckle.
3. Nuts (14, 35).
supported as on a twin-post hoist so that the front

coil spring remains compressed, yet the wheel and
steering knuckle assembly remain accessible. If a
frame hoist is used, support the lower control arm
with an adjustable jackstand to safely retain the
spring in its curb height position.
Wheel and tire assembly.
Caliper.
Refer to BRAKES (SEC. 5).
Hub/Rotor (81).
Refer to Wheel Hub, Bearing and Race, in this
section.
4. Splash shield (71).
Bolts (83) and washers (84).
Gaskets (85).
5. Steering knuckle from the tie rod end.
Refer to STEERING LINKAGE (SEC. 3B1).
6. Steering knuckle (70) from the upper ball joint (13).
Position a floor jack under the lower control arm
(36) near the spring seat.
Raise the jack until it just supports the lower
control arm.
Use J-23742 to break the upper ball joint free of
the steering knuckle (figure 15).
Raise the upper control arm (28) to disengage
the upper ball joint from the steering knuckle.
Im portant
Floor jack must remain under the lower control
arm s p rin g s e a t d u rin g re m o v a l and
installation to retain the spring and the lower
control arm in position.
R10/1500, G 10/1500 and G20/2500 models.

Nut (14) to 68 N m (50 ft. lbs.).
Nut (35) to 122 N m (90 ft. lbs.).
All other models.
Nuts (14, 35) to 122 N m (90 ft. lbs.).
4. Cotter pins (15, 34).
Tighten the nuts (14, 35), if needed.
Im portant
5.
6.
7.
8.
R10/1500, G10/1500 and G20/2500 models.

Nut (14), maximum torque to align the
cotter pin is 122 N m (90 ft. lbs.).
Nut (35), maximum torque to align the
All other models.
Nuts (14, 35), maximum torque to align the
Remove the floor jack.
Gasket.
Tie rod end to the steering knuckle (70).
Splash shield (71).
Washers (84) and bolts (83) in position.
&
Tighten
Bolts (83) to 13.5 N-m (120 in. lbs.).

4. Hub/rotor assembly.
Refer to Wheel Hub, Bearing and Race in this
section.
5. Caliper.
Refer to Wheel Bearing Adjustment in this
section.
NOTICE: For steps 3, 5 and 6, refer to the

Notice onpage3C-1 of this section.
Install or Connect Connect (Figures 5 through
8 and 17)
Tools Required:
J-23028-02 Spring Remover
1. Coil spring (32) into position on the lower control
arm (36).
Important
Install a chain around the coil spring and through
the lower control arm as a safety precaution.
CAUTION: Failure to secure J-23028 to a

suitable floor jack could result in personal
injury.
7. Check the front alignment and reset as required.

Refer to FRONT END ALIGNMENT (SEC. 3A).
8. Wheel and tire assembly, and lower the vehicle to the
ground.
2 . Slowly lift the lower control arm into position.

Line up the front indexing hole in the shaft (50)
with the crossmember attaching studs.
Do not damage the lower ball joint (37).
Use J-23028-02 bolted on a floor jack.
3. U-bolts (44), washers (48), and nuts (49).
Tighten
COIL SPRING
|+ + | Remove or Disconnect (Figures 5 through 8,
and 17)
Tools Required:
J-23028-02 Spring Remover
stands, allowing the control arms to hang free.
Remove the wheel and tire assembly.
1. Shock absorber (20) at the lower end and move it
aside.
Nuts (38), bolts (43), washers (41) and clamp
(42).
C A U T IO N : F a ilu re to s e c u re J -2 3 0 2 8 to a
s u ita b le flo o r ja c k c o u ld re s u lt in p erso n a l
in ju ry.
3. J-23028-02 to a suitable jack.
4. Place J-23028-02 under the lower control arm shaft
(50) as shown in figure 17.
Im portant
Install a chain around the coil spring (32) and through
the lower control arm (36) as a safety precaution.
5. Raise the jack to remove the tension from the lower
control arm shaft (50) and remove the U bolts.
Nuts (49) and washers (48).
6. Lower the control arm by slowly releasing the jack until
the spring can be removed.
Do not damage the ball joint (37) by applying too
much force on it.
7. Spring (32) and safety chain only after all compression
is removed from the spring.
Proper maneuvering of the spring will allow for
easy removal.
G 10/1500-20/2500 models to 88 N m (65 ft.

lbs.).
All other m odels to 115 N-m (85 ft. lbs.).
Lower the floor jack, and remove J-23028-02.
Stabilizer bar (59) to the lower control arm (36).
Clamp (42), washers (41), bolts (43) and nuts
(38).
Nuts (38) to 33 N-m (24 ft. lbs.).
6. Shock absorber (20) to the lower control arm (36).

Washer (22), bolt (21), and nut (23).
Tighten
R models.
Bolt ( 2 1 ) to 80 N-m (59 ft. lbs.).
G models.
Bolt (21) to 103 N-m (80 ft. lbs.).
P models.
Nut (23) to 80 N m (59 ft. lbs.).
7 . Check the front end alignment.
8. Wheel and tire and lower the vehicle.
LOWER BALL JOINT

Inspect (Figures 5 through 8, and 18)
1. Raise the vehicle and remove the wheel and tire
assembly. Support the weight of the control arms at
the wheel hub and drum.
2. Measure the distance between the tip of the ball
joint stud and the tip of the grease fitting below the
ball joint (figure 18).
3. Move the support to underneath the control arm
allowing the wheel hub and drum to hang free.
4. Measure the distance as in Step 2.
If the difference in measurements exceeds 2.38

mm (3/32 inches), for all models, the ball joint is
worn and must be replaced.
5. If the ball joint seals are cracked, cut, or torn, replace
them.
* Remove or Disconnect (Figures 5 through 8,

and 19)
Tools Required:
J-9519-7 Ball Joint Remover
J-9519-28 Ball Joint Remover
J-21474-30 Ball Joint Fixture
Raise the vehicle on a hoist. If a frame hoist is used it
will be necessary to support the lower control arm with
a floor stand. Remove the tire and wheel assembly.
1. Cotter pin (34), nut (35), and lube fitting (12).
Loosen (two turns) but do not remove the nut
(35).
Use J-23742 between the ball joint studs (figure

16).
It may be necessary to remove the caliper and
wire it to the frame to gain clearance for J-23742.
Extend J-23742 until the lower ball joint (37)
breaks free from the steering knuckle (31).
Remove the nut (35) and J-23742.
3. Hub/rotor (70) and the knuckle assembly off the lower
ball joint (37).
Install J-21474-13, J-9519-7, J-9519-28, and J9519-30 (figure 19).
4. Ball joint (37) from the lower control arm (36).
Install J-21474-13, J-9519-22, J-9519-16, and
J-9519-10 (figure 19).
Turn the hex head screw until the ball joint is free
of the lower control arm.
Remove the tools and the ball joint (37).

20)
Figure 19Removing the Lower Ball Joint
Tools Required:
J-9519-16 Ball Joint Installer
1. Ball joint (37) into the lower control arm (36).
Start the ball joint into the control arm and install
J-9519-16 and J-9519-30 (figure 20).
Position the bleed vent in the rubber boot facing
inward.
Turn the hex head screw until the ball joint is
seated in the lower control arm.
2. Ball joint into the steering knuckle (31).

Mate the steering knuckle (31) to the lower ball
joint (37).
3. Caliper if it was removed.
NOTICE: Refer to N o tic e on page 3 C - 1 of
this section.
4. Nut (35).
Tighten
Nut (35) to 122 N-m (90 ft. lbs.).
5. Cotter pin (34).
Tighten the nut (35) if needed.
Important
Maximum torque to align the cotter pin is 175
N-m (130 ft. lbs.).
5. Fitting (12).
Lubricate the ball joint (37) with recommended
lubricant.
6. Tire and wheel assembly and lower the vehicle to the
floor.
UPPER BALL JOINT

Inspect
The upper ball joint (13) is spring loaded in its
socket. Replace the ball joint if there is any lateral
shake or if it can be twisted in its socket with the
fingers.
The ball joint seals for cuts or tears. Replace the ball
joint if any are found.

and 15)
Tools Required:
Raise the vehicle on a hoist. If a frame hoist is
used, support the lower control arm with a
floor jack.
1. Cotter pin (15) from the upper ball joint (13).
Loosen the nut (14) two turns, but do not remove
the nut.
2. Caliper.
3. Upper ball joint (13) from the steering knuckle (31).
Use J-23742 to separate the upper ball joint from
the steering knuckle (figure 15).
Nut (14), and lift the upper control arm (28) free
of the ball joint.
4. Ball joint (13) from the upper control arm (28).
Drill 6.35 mm (1/4 inch) deep holes in the rivet
heads using a 3.175 mm (1/s inch) diameter drill
bit.
Drill off the rivet heads using a 12.7 mm (V2 inch)
diameter drill bit.
Punch out the rivets and remove the upper ball
joint from the upper control arm.
NOTICE: For steps 1 and 2 refer to the N otice
on page 3 C - 1 of this section.
-4- Install or Connect (Figures 5 through 8, and
21 )
Upper ball joint (13) into the upper control arm (28).
Position into the upper control arm and install
four attaching bolts and nuts (A) (figure 21).
Nuts (A) to 25 N m (18 ft. lbs.).

2. Upper ball joint to the steering knuckle (31).
The upper ball joint must be fully seated into the
steering knuckle.
Nut (14).
Tighten
R10/1500, G10/1500 and G20/2500 models.
Nut (14) to 68 N-m (50 ft. lbs.).
All other models.
Nut (14) to 122 N-m (90 ft. lbs.).
3. Cotter pin (15).
Tighten the nut (14) if needed.
Im portant
R10/1500, G 10/1500 and G20/2500 models.
Maximum torque to align the cotter pin is
122 N-m (90 ft. lbs.).
All other models.
175 N-m (130 ft. lbs.).
4. Upper ball joint grease fitting (12).
5. Grease the upper ball joint (13).
Use a recommended lubricant.
Figure 22Removing the Lower Control Arm

Bushings (R10/1500, G10/1500 and G20/2500 Models)
6. Caliper.
7. Tire and wheel assembly.
8. Check the front end alignment.
LOWER CONTROL ARM PIVOT

SHAFT AND BUSHINGS
R10/1500 SERIES MODELS

22)
Tools Required:
J-23028-02 Coil Spring Remover
J-22717 Lower Control Arm Bushing Stake
Remover
J-24435-2 Lower Control Arm Bushing Spacer
J-24435-3 Lower Control Arm Bushing Remover
J-24435-7 Lower Control Arm Bushing Fixture
If just the bushings (46) or the pivot shaft (50) need
replacement, the lower control arm (36) does not have to
be removed from the vehicle.
Raise the vehicle on a hoist and support the frame so
the lower control arms hang free.
CAUTION: Failure to install J-23028-02 to a

injury.
1. J-23028-02 to a suitable floor jack and raise it into
position [under the lower control arm (26)] inboard of
the spring and into the depression of the lower
control arm.
Im portant
Install a chain over the upper control arm (28)
inboard of the stabilizer bar (59) and outboard of the
shock absorber (20).
2. Shock absorber (20) from the lower control arm (28).
Figure 23 Installing the Lower Control Arm Bushings

(R10/1500, G10/1500 and G 20/2500 Models)
Nut (23), washer (22), and bolt (21).
Nuts (38), washers (39, 41), clamp (42), and bolts
(43).
4. Pivot shaft end nuts (24).
Loosen only, do not remove.
5. Lower control arm from the frame.
Nuts (49), washers (48), and U-bolts (44).
SLOW LY low e r th e flo o r ja c k u n til all
compression is released from the spring (32).
6. Stakes on the front bushing.
Use J-22717 or an equivalent tool.
7. Bushings (46) and the pivot shaft (50) from the lower
control arm (36).
Use J-24435-2, J-24435-3, J-24435-6, and
J-24435-7 (figure 22).
Tighten the bolt on J-24435-7 to remove the
bushing. Discard the old bushing.
The pivot shaft (50) will slide out of the lower
control arm after one bushing is removed.
Leave the pivot shaft (50) inside the lower control
arm (36) to remove the remaining bushing.
NOTICE: For steps 3, 4, 5 and 6, refer to the
Install or Connect (Figure 5, 8 and 23)

Tools Required:
J-23028-02 Coil Spring Compressor
J-24435-4 Lower Control Arm Bushing Installer
1. Bushings (46) and the pivot shaft (50).
Use J-24435-4, J-24435-6, and J-24435-7 (figure
23).
Tighten the bolt on J-24435-7 to install the
bushings.
Install one bushing, then insert the pivot shaft
and install the remaining bushing.
Make sure J-24435-6 is in position to prevent
collapsing the control arm.

2. Stake the front bushing in at least two places.
CAUTION: Failure to secure J-23028-02 to a

injury.
3. Lower control arm (36) to the frame.
SLOWLY raise the floor jack until the front
indexing hole in the pivot shaft (50) lines up with
the crossmember attaching studs.
Do not damage the ball joint (37).
J-23028-02 is bolted to a suitable floor jack.
U-bolts (44), washers (48), and nuts (49).
1.
2.
3.
4.
Tools Required:
New bushing (46) using J-24435-6, J-24435-4, and
J-24435-7 (figure 23).
Tighten J-24435-7 until the bushing fully seats.
The outer tube hole must be lined up so it faces
to the front or forward to the staked bushing.
Stake the front bushing in at least two places.
Pivot shaft (50) into installed bushing.
Remaining bushing (46) into the lower control arm.
Tighten
U-bolt nuts (49) to 115 N-m (85 ft. lbs.).

Pivot shaft end nuts (24).
NOTICE; Refer to N otice on page 3 C - 1 of

this section.
5. Pivot shaft washers (25) and nuts (24).
Nuts (24) to 95 N-m (70 ft. lbs.).

5. Stabilizer bar (59) to the lower control arm (28).
Washers (39, 41), clamp (42), bolts (43), and nuts
, (38).
Tighten
Nuts (38) to 34 N-m (25 ft. lbs.).
6. Shock absorber (20) to the lower control arm (36).
Washers (22), bolt (21), and nut (23).
Tighten
Nut (23) to 81 N-m (60 ft. lbs.).
8. Wheel and tire and lower the vehicle.
G10/1500-20/2500 MODELS
(EXCEPT 20/2500 MODELS W/6.2L DIESEL)
|+-| Remove or Disconnect (Figures 6, 8, and 22)
1.
2.
3.
4.
Tools Required:
J-22717 Lower Control Arm Bushing Stake
Remover
Lower control arm.
Refer to Lower Control Arm, in this section.
Pivot shaft nuts (24) and washers (25).
Rear bushing (46).
Place the lower control arm in an arbor press.
Press the front end of the pivot shaft (50) to
remove the rear bushing. Discard the old
bushing.
The pivot shaft can be removed at this time.
Front bushing (46).
Stakes from the front bushing using J-22717 or
an equivalent tool.
Use J-24435-7, J-24435-3, J-24435-2, and
J-24435-6.
Tighten J-24435-7 until the bushing comes free.
Discard the old bushing (figure 22).
Tighten
Nuts (24) to 156 N m (115 ft. lbs.).
6. Lower control arm (76).
This results with the vehicle being completely
assembled and lowered to the ground.
G20/2500 MODELS WITH RPO LH6/LL4

6.2L DIESEL ENGINE)
and 25)
Tools Required:
Refer to Lower Control Arm , in this section.
2. Bushings (46) and the pivot shaft (50) from the lower
control arm (36).
25).
Tighten the clamp (J-24435-7) to remove the
bushing (46).
The pivot shaft can be slipped out at this time.
Repeat the procedure on the remaining bushing
(46) to remove it from the lower control arm (36).

26)
Tools Required:
1. Bushings (46) and the pivot shaft (50) into the lower
control arm (36).
26).
Tighten the clamp (J-24435-7) to install the
bushing (26).
Slide the pivot shaft (50) into the lower control
arm (36), then install the other bushing (36).
B
A. Rear End
B. F ro n t End
C. In s u la to rs
D. In n e r P ivot S h a ft
E. S h a ft Tube
F. O -R ing
G. W asher, C o lla r and F la n g e

H. B u m p e r
I. S h a ft R e s tric to r
B-07514
Figure 24Lower Control Arm Pivot Shaft (G10/1500 and G20/2500 Models w/o 6.2L Diesel)
This results with the vehicle being completely
assembled and lowered to the ground.
SLOWLY lower the floor jack to access the pivot

shaft (50).
5. Grease fittings (12).
R-P20/2500-30/3500, G30/3500 MODELS
6. Bushings (46) and bushing seals, and pivot shaft (50).
|+ + | Remove or Disconnect (Figures 5 through 8)

Raise the vehicle and support the frame so the
control arms hang free. Remove the tire and wheel
assembly.
1. Position an adjustable floor jack under the lower
control arm (36) inboard of the spring and into the
depression in the lower control arm.
Important
inboard of the stabilizer bar (59) and outboard of the
shock-absorber (20).
2. Shock absorbers (20) from the lower control arm
(36).
Nut (23), washer (22) and bolt (21).
Nuts (38), washers (39, 41), bolts (43) and clamp
(42).
4. Lower control arm (36) from the frame crossmember.
Nuts (49), washer (48), and U-bolts (44).
J-24435-7
Unscrew the bushings.

Slide the pivot shaft out of the lower control arm.
Seals are mounted between the bushings and
the pivot shaft. Discard the old seals.
NOTICE: For steps 1, 3, 4, and 5 refer to the

Notice onpage3C-1 of this section.
++

27)
1. Pivot shaft (50), seals, and bushings (46), to the

lower control arm (36).
New seals onto the pivot shaft.
Pivot shaft into the lower control arm. Attach the
bushings. Center the shaft in the lower control
arm (figure 27).
&
Tighten
Bushings (46) to 379 N m (280 ft. lbs.).
J-24435-7
J-24435-4
J-24435-5
(Hidden)
J-24435-3
J-24435-1
B-07479
Figure 25Removing the Lower Control Arm Bushing

(G20/2500 W/6.2L Diesel)
B-07481
Figure 26Installing the Lower Control Arm Bushing

(G20/2500 w/6.2L Diesel)
2.96 31.9 mm
(1.16 -1.25 inch es)
To P ro pe rly C e n te r
The Pivot S h a ft
36. L o w e r C o n tro l A rm
46. B u s h in g
50. P ivot S h a ft
B. B u s h in g Seal
B-07478
Figure 27Centering the Lower Control Arm Shaft

(R-P20/2500, 30/3500 and G30/3500 Models)
Inspect
Pivot shaft (50) for free rotation.
2. Grease fitting (12).
Lubricate the bushings with an approved grease.
Refer to MAINTENANCE AND LUBRICATION
(SEC. 0B).
3. Lower control arm (36) to the frame crossmember.
SLOWLY raise the floor jack until the lower control arm
(36) is in position.
Important
Be sure the hole in the pivot shaft mates with
the bolt head in the fram e crossm em ber
saddle.
Tighten
Nuts (49) to 115 N-m (85 ft. lbs.).
Stabilizer bar (59) to the lower control arm (36).
Nuts (38), washers (39, 41), bolts (43), and clamp
(42).
Tighten
Nuts (38) to 33 N-m (24 ft. lbs.).

Shock absorbers (20) to the lower control arm (36).
Bolt (21), washer (22), and nut (23).
Tighten
Figure 28Removing the Upper Control Arm

Bushings (R10/1500, G10/1500 and G20/2500 Models)
UPPER CONTROL ARM PIVOT

SHAFT AND BUSHINGS
R10/1500, G10/1500-20/2500 MODELS
and 28)
Tools Required:
1. Upper control arm (28).
Refer to Upper Control Arm , in this section.
2. Nuts (24), bushings (26) and the pivot shaft (29) from
the upper control arm (28).
28).
Tighten J-24435-7 to remove the bushing (26).
Pivot shaft (29) can be pulled free at this time.
Repeat this procedure on the remaining bushing
(26). Discard the old bushings.

29)
Tools Required:
NOTICE: Refer to the N o tic e on page 3 C - 1
of this section.
R models.
Bolt (21) to 80 N-m (59 ft. lbs.).
G models.
Bolt (21) to 103 N-m (80 ft. lbs.).
P models.
Nut (23) to 80 N-m (59 ft. lbs.).
Remove the safety chain and the floor jack. Install the
tire and wheel assembly and lower the vehicle to the
ground.
1. Bushings (26) and the pivot shaft (29) into the upper
control arm (28).
29).
Tighten the clamp (J-24435-7) to install the
bushing (26).
Slide the pivot shaft (29) into the upper control
arm (28), then install the other bushing (26).

|-n-| Install or Connect (Figures 6 through 8, and
30)
1. Pivot shaft (29), seals, and bushings (26) onto the
upper control arm (28).
New inner seals onto the pivot shaft.
Slide the pivot shaft into position inside the
upper control arm. Screw on the new bushings.
Do not tighten.
9
Im portant
The pivot shaft (29) must be centered in the upper
control arm (28) as shown in figure 30.
Tighten
Bushings (26) to 257 N-m (190 ft. lbs.).
L*
Figure 29Installing the Upper Control Arm Bushings
(R10/1500, G10/1500 and G20/2500 Models)
Inspect
Pivot shaft for free rotation.

2. Grease fitting (12).
G rease the b u s h in g s (29). R efer to
MAINTENANCE AND LUBRICATION (SEC. 0B).
Nuts (24) in place.
Tighten
Nuts (24) to 156 N-m (115 ft. lbs.).
Upper control arm (28) to the crossmember.
Refer to Upper Control Arm, in this section.
Caliper if it was removed.
5. Remove the supports and lower the vehicle to the
ground.
R-P20/2500-30/3500, G30/3500 MODELS

Raise the vehicle and support the lower control
arms with a floor jack positioned under or near the
ball joint assembly. Remove the wheel and tire
assembly.
1. Loosen, but do not remove the pivot shaft to frame
nuts (27).
2. Shim packs (18).
Tape each pack together and mark their position
to assure exact replacement during installation.
3. Pivot shaft to frame nuts (27), bolts (4), and spacers
(19).
Do not allow the upper control arm (28) to swing
too far from the frame crossmember.
Im portant
inboard of the stabilizer bar (59) and outboard
of the shock absorber (20), to retain the upper
control arm in a close relationship to the frame
crossmember.
4. Pivot shaft (29) and bushings (26).
Grease fitting (12).
Unscrew the bushings (26).
Slide the pivot shaft out of the upper control arm.
Remove and discard the inner seals (between
the bushings and the pivot shaft).
NOTICE: Refer to the Notice on page 3C-1 of

this section.
3. Pivot shaft (29) to the frame.
Bolts (4), shim packs (18), spacers (19), and nuts
(27).
Shims are positioned into their original positions.
Make sure the convex and concave sides of the
shims are together.
Tighten
Nuts (27) to 142 N-m (105 ft. lbs.).
4. Remove the safety chain and install the wheel and tire
assembly.
6. Lower the vehicle to the ground.
LOWER CONTROL ARM
++
1.
2.
3.
4.

and 16)
Tools Required:
Caliper.
Coil spring (32).
Refer to Coil Spring, in this section.
The lower control arm is separated from the
frame.
Use a jack to support the inboard end of the lower
control arm (36).
Lower control arm (36) from the steering knuckle (31).
Cotter pin (34), then loosen the nut (35) one turn.
Install J-23742, with the large cup end over the
upper ball joint nut (14). Extend threaded end
until the ball joint stud loosens from the steering
knuckle. Remove J-23742 and the nut (35).

1. Lower control arm (36) to the steering knuckle (31).
Position the lower control arm ball joint stud (37)
into the steering knuckle (31).
Nut (35) onto the stud. Do not tighten.
2. Coil spring (32).
Refer to Coil Spring, in this section.
This step results with the lower control arm being
attached to the frame.
NOTICE: Refer to Notice on page 3C-1 of

this section.
3. Nut (35) and cotter pin (34).
Tighten
Nut (35) to 122 N m (90 ft. lbs.).
Tighten the nut if needed to install the cotter pin.
| 9 | Important
Maximum torque to align the cotter pin is 175
N m (130 ft. lbs.).
4. Caliper.
6. Tire and wheel assembly and lower the vehicle.
UPPER CONTROL ARM

and 15)
Tools Required:
stands. Remove the wheel and tire assembly. Place
an adjustable jackstand under the lower control arm
for support.
1. Caliper.
2. Upper control arm (28) from the steering knuckle (31).
Cotter pin (15).

Loosen the nut (14). Do not remove it.
Install J-23742 with the large cupped end over
the lower control arm ball joint stud nut (35).
Expand J-23742 until the upper control arm
separates.
Nut (14) from the upper ball joint stud and raise
the upper control arm to clear the steering
knuckle.
3. Upper control arm (28) from the frame bracket (9).
Nuts (27), spacers (19), shims (18), washers (5)
and bolts (6).
9
Im portant
Tape the sh im s to g e th e r in th e ir o rig in a l
positions and tag for proper relocation.
+- Install or Connect (Figures 5 through 8)
NOTICE: For steps 2 and 3, refer to Notice on

page 3C-1 of this section.
1. Shims (18) into position on the upper control arm
frame bracket (9).
Make sure the shims are positioned with concave
and convex sides together.
2. Upper control arm (28) to the frame bracket (9).
Spacers (19) and nuts (27), washers (5), and
bolts (6).
Im portant
A normal shim pack will leave at least two
threads of the bolt (6) exposed beyond the nut.
If two threads cannot be obtained; check for
damaged control arm or related parts. The
difference between the front and rear shim
packs must not exceed 7.62 mm (0.30 inches).
The front shim pack must be at least 6.09 mm
(0.24 inches).
Always tighten the thinner shim packs nut (27)
first for improved shaft to frame clam ping force
and torque retention.

Tighten
R10/1500, G 10/1500 and G20/2500 models.
Nuts (27) to 95 N m (70 ft. lbs.).
All other models.
Nuts (27) to 142 N m (105 ft. lbs.).
3. Upper control arm (28) to the steering knuckle (31).
Insert the upper control arm ball joint stud (13)
into the steering knuckle (31).
4. Nut (14) and cotter pin (15).
Tighten the nut if needed to install the cotter pin.
Tighten
R10/1500, G 10/1500 and G20/2500 models.
Nut (14) to 68 N m (50 ft. lbs.).
All other models.
Nut (14) to 122 N m (90 ft. lbs.).
| ? | Im portant
R10/1500, G10/1500 and G20/2500 models.
122 N m (90 ft. lbs.).
All other models.
175 N m (130 ft. lbs.).
5. Caliper.
7. Wheel and tire assembly. Lower the vehicle to the
ground.
SUSPENSION UNIT
The front suspension and frame crossmember can be
removed or installed as a unit if extensive service is
required.
Remove or Disconnect (Figure 5 through 8,

and 31 through 33)
Raise the hood and disconnect the battery negative
cable.
Hoist the vehicle and support it with suitable safety
stands placed at the frame side rails. Remove the
tire and wheel assembly and then lower the hoist.
1. Front brake hose clip from each upper control arm.
2. Brake hoses from the calipers.
Clean the area adjacent to the brake hose
fittings.
Discard the special washers (2 on each hose)
and cover the disconnected ends of each hose
with suitable material.
3. Tie rod ends from the steering knuckle (31).
4. Front stabilizer from the lower control arms (36).
Nuts (38), washers (39, 41), bolts (43), and
clamps (42).
5. Shock absorbers (20) from the lower control arms (36).
Nut (23), washer (22), and bolt (21).
6. Brake line clip bolts from the front suspension
crossmember.
On C series models the clip is located under the
right side engine mount support bracket.
NOTICE: Failure to disconnect these clips from

the suspension u nit w ill result in severe
damage to the brake line when the unit is
lowered from the vehicle.
7. Suspension crossmember from the engine mounts.
Refer to ENGINE (SEC. 6A).
8. Suspension crossmember from the frame rail (figure
31).
9. R a is e th e h o is t to s u p p o r t th e s u s p e n s io n
crossmember.
10. Support the engine.
Must be done before the suspension unit is
lowered from the vehicle.
11. Suspension unit and crossmember from the vehicle.
Upper control arm bracket to the frame side rail
nuts (10), washer (7), and bolts (6).
Lower the suspension unit and the crossmember
to bring the unit clear of the vehicle.
NOTICE: For steps 3, 7, and 8, refer to the

Notice on page 3C-1 of this section.
Install or Connect (Figures 5 through 8 and 31
through 33)
1. Position the new suspension unit and crossmember
and raise it with the hoist to align the suspension
crossmember and frame holes.
2. Suspension crossm em ber to the frame rail bolts
(figure 31).
3. Upper control arm (28) and the frame bracket bolts
(6 ).
Washers (7) and nuts (10). Do not tighten.
Tighten
R models.
Bolts (6) to 87 N m (64 ft. lbs.), except
R30/3500 with F42.
Bolts (6) to 135 N m (100 ft. lbs.), R30/3500
with F42.
G models.
P models.
Bolts (4, 6) to 87 N m (64 ft. lbs.), except
P30/3500 motor home.
Bolts (4, 6) to 135 N-m (100 ft. lbs.),
P30/3500 motor home.
Important
The upper control arm to frame bracket bolts
must be tightened first.
The crossmember must be in contact with the
frame side rails.
4. C ro ssm em be r to fram e b olts (1), th ro u g h the
reinforcement (8).
Washers (2) and nuts (3) as used.
Tighten
R30/3500 models with F42.
Nut (3) to 180 N-m (133 ft. lbs.).
P30/3500 motro home.
Bolt (1) to 290 N-m (214 ft. lbs.).
A.
B.
C.
D.
E.
1.
2.
3.
4.
5.
6.
7.
8.
10.
17.
85.
86 .
87.
R10/1500 M o d e ls
R20/2500 and R30/3500 M o d e ls w ith o u t F42
R30/3500 M o d e ls w ith F42, E xte n d e d C ab and C h a s s is C ab
E n g in e M o u n tin g B ra cke t
B o lt
B o lt
W a sh er
N ut
B o lt
W asher
B o lt
W asher
N ut
W a sh er
B o lt
W asher
C ro s s m e m b e r
B-07727
Figure 31R Model Suspension Unit Attachment
5.
6.
7.
8.
1.
2.
4.
5.
6.
7.
17.
B o lt
W a sh e r
B o lt
W a sh e r
B o lt
W a sh e r
W a sh e r
All other models.

Bolt (1) to 125 N m (92 ft. lbs.).
Engine mount support bracket to the suspension
crossmember bolts.
Remove the engine support and lower the hoist.
Refer to ENGINE (SEC. 6A).
Brake line clip to the crossmember.
Shock absorber to the lower control arm (28).
Washers (22), nuts (23), and bolts (21).
Tighten
B-07726
Figure 32G Model Suspension Unit Attachment
R models.
Bolt (21) to 80 N-m (59 ft. lbs.).
G models.
Bolt (21) to 103 N-m (80 ft. lbs.).
P models.
Nut (23) to 80 N-m (59 ft. lbs.).
9. Stabilizer bar (59) to the lower control arm (28).
Clamps (42), bolts (43), washers (39) and nuts
(38).

A.
B.
D.
E.
P20/2500 and 30/3500 M o d e ls

P30/3500 M o to rh o m e
E n gin e M o u n tin g B ra cket
B o lt
1. B o lt
2. W a sh er
5. W a sh er
6. B o lt
7. W a sh er
8.
10.
85.
86.
87.
N ut
B o lt
W a sh er
C ro s s m e m b e r
B-07724
Figure 33P Model Suspension Unit Attachment
R and P models.
Nuts (38, 58) to 33 N m (24 ft. lbs.).
G models.
Nut (38) tro 29 N m (21 ft. lbs.).
Bolt (54) to 33 N-m (24 ft. lbs.).
10. Tie rod ends to the steering knuckle (31).
11. Brake hose to the caliper.

12. Brake hose clips to the upper control arms.
13. Bleed the brake system.
14. Tires and wheels and lower the vehicle.
15. Battery cable.
ON-VEHICLE SERVICE:
I-BEAM (RPO FS3) FRONT SUSPENSION
SHOCK ABSORBER
I++I Remove or Disconnect (Figures 34 through 36)
1. Shock absorber (113) from the leaf spring spacer
(158).
Nut (109) and washer (111).
Pull the shock free from the vehicle.
L*
Inspect


1. Shock absorber (113) to the frame (figure 36).
Insert the shocks upper stud into the hole in the
frame.
Washer (111) and nut (109). Do not tighten.
NOTICE: Refer to the N o tice on page 3 C - 1
of this section.
2. Shock absorber (113) to the leaf spring spacer (158)
(figure 36).
Position the shocks lower mount onto the stud.
Washer (111) and nut (109).
Tighten
Shock absorber upper nut to 185 N-m (136 ft.
lbs.).
Figure 34P Model I-Beam Front Suspension Components

101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
Spring Hanger
Rivet
Spring Stop
Hanger B ushing
W asher
Bolt
Shackle
Nut
Nut
Nut
W asher
Bum per
Shock A bsorber
Spacer
Nut
S tabilizer Link
Retainer
Insulator
Bolt
W asher
Brake H ose Bracket
Cap
Gasket
King Pin
Bushing
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
146.
147.
148.
149.
Spacer
Steering Knuckle
F ittin g
Nut
Dust Seal
Shim
Nut
W asher
Lock Pin
Nut
Nut
Thrust Bearing
Nut
C otter Pin
Steering And Third Arm
Splash Shield
Brake C aliper
W asher
Bolt
A nchor Plate
Stop Bolt
Stop Nut
Retainer/Cap
C otter Pin
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
171.
172.
173.
Nut
Washer
O uter W heel Bearing And Race
W heel Hub Bolt
H ub/Rotor
Inner W heel Bearing And Race
Bearing Seal
Front Axle
Spring Spacer
Spring Leaf
Bolt ~
Spacer
Front Spring
Nut
Spacer
U-Bolt
S tabilizer Bar
Insulator
Clamp
Bolt
Nut
W asher
Bolt
Spring Hanger
B-07485
Figure 35P Model I-Beam Front Suspension Components
109
Shock absorber lower nut to 50 N-m (37 ft.

lbs.).
3. Wheel and tire on the vehicle. Lower the vehicle to the

ground.
STABILIZER BAR
|<"+| Remove or Disconnect (Figures 34, 35, and
37)
Tools Required:
J-6627-A Wheel Stud and Tie Rod Remover
stands. Remove the tire and wheel assembly.
1. Stabilizer bar (166) from the stabilizer link (116).
Use J-6627-A to separate the stabilizer link from
the stabilizer end.
2. Stabilizer bar (166) from the frame (figure 37).
Nuts (170), washers (171), clamp bolts (169) and
clamps (168).
Slide the insulator (167) from the stabilizer bar
(166).
3. Stabilizer link (116) from the front axle (157) (figure 37).
Nut (136), retainer (117), insulator (118).
B-07487
Pull the link from the axle. Another insulator (118)

and retainer (117) will come off the link.
118 \
^1181 A.
n y 114.
166.
167.
168.
169.
170.
171.
115.
116.
117.
118.
136.
S ta b iliz e r Bar
In s u la to r
C la m p
B o lt
N ut
W a sh e r
B-07491
Install or Connect (Figures 34, 35, and 37)
1. Stabilizer link (116) to the front axle (157) (figure 37).

Slide a retainer (117) and an insulator (118) on to
the link and insert the link into the proper hole in
the front axle.
Insulator (118), retainer (117) and nut (136).
Tighten
Nut (136) until the distance between each
retainer (117) is 2.08 cm (0.82 inches) (figure
37).
2. Stabilizer bar (166) to the frame (figure 37).
Tighten
Nuts (115) to 68 N m (50 ft. lbs.).
ground.

|<-+| Remove or Disconnect (Figures 34 and 35)
1. Caliper (142).
Insulators (167) onto the stabilizer bar (166).

Clamps (168), clamp bolts (169), washers (171),
and nuts (170).
Nuts (170) to 28 N m (21 ft. lbs.).

3. Stabilizer bar (166) to the stabilizer link (116).
NOTICE: Support the caliper with a piece of

wire to prevent damage to the brake line.
2. Wheel hub/rotor (154) (figures 34, 35).
Retainer/cap (148).
Cotter pin (149), nut (150) and washer (151).
Pull the hub/rotor free from the spindle, making
sure the outer wheel bearing (152) comes free.

threads.
3. Inner wheel bearing (155).
Pry out the sea! (156).
4. Races.
Drive out each race using a brass drift.
131 Clean
1. Grease from the h ub /ro to r (154) and steering

knuckle spindle.
Grease from inside the hub.
2. Grease from the wheel bearings (152, 155) and races.
bristles).
Do not spin the wheel bearings with compressed
air to dry themthe wheel bearings may be
damaged.
Inspect
1. W heel bearings (152, 155) and th eir races for
damage or wear.
section.
replace both.
2. Hub/rotor (154) for damage or wear.
Check for out-of-round or scored conditions.
Check for pitting or cracks.
Repair or replace as necessary.

Tools Required:
J-29040 Outer Bearing Race Installer
NOTICE: Start the races squarely inside the
hub/rotor (154) to avoid distortion and possible
cracking.
1. Races into the hub/rotor (154).
Place the hub/rotor on J-9746-02 and rest this
assembly on press bars.
Use J-29040 to drive the outer bearing race into
position.
Remove J-9746-02 and use a 7.6 cm (3 inch)
diameter bar, or equivalent tool to drive the inner
bearing race into position. If the bar is larger
than 7.6 cm (3 inches), it may damage the
bearing seal seat.
Im portant
Use an approved high tem perature front wheel
bearing grease to lubricate the bearings. Refer to
Do not mix different greases as mixing may change
th e g re a s e s p ro p e rtie s r e s u ltin g in p o o r
performance.
2. Apply a thin film of grease to the steering knuckle
spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each
wheel bearing retainer/cap (148).
4. Fill each wheel bearing (cone and roller assembly)

full of grease.
Use a cone-type grease machine that forces
If a cone-type grease machine is not available,
pack the wheel bearing by hand.
When packing the wheel bearing by hand, work
the grease into the bearings between the rollers,
bearing (cones, rollers, and cage) with grease
and/or wear.
5. Inner wheel bearing (155) into the hub/rotor (154).
this bearing.
6. New seal (156).
Use a flat plate or block to install the seal to
insure it is flush with the hub/rotor flange.
7. Hub/rotor (154).
threads.
Slide it over the spindle until the wheel bearing
(152) fully seats against the hub/rotor outer race.
of this section.
9. Washer (151), nut (150) and cotter pin (149).
Do not place the cotter pin through the hole in
the sp in d le u ntil the w heel bearings are
adjusted.
Tighten
Nut (150) to 16 N m (12 ft. lbs.) while turning
the hub/rotor assembly in either direction.
10. Put an additional amount of grease outboard of the
wheel bearing (152).
section.
12. Retainer/cap (148) in place.
13. Caliper (142).
14. Tire and wheel assembly. Lower the vehicle to the
ground.
WHEEL BEARING ADJUSTMENT

| ? | Im portant
ca nn ot be m aintain ed unless the fro n t w heel
bearings are correctly adjusted. The bearings must
be a slip fit on the spindle and the inside diameter of
the wheel bearing must be lubricated to ensure the
bearings will creep. The spindle nut (150) must have
a free-running fit on the spindle threads.

N O T IC E : N e v e r p r e lo a d th e fro n t w h e e l
bearings. Damage can result by the steady
thrust on the roller ends which comes from
preloading.
ft
A djust
stands under the lower control arms.
Remove the retainer/cap (148).
Remove the cotter pin (149).
Tighten
Nut (150) to 16 N-m (12 ft. lbs.) while rotating
the wheel and tire assem bly (or the hub/rotor).
This will seat the bearings.
3. Back off the nut (150) one flat.
If the hole in the spindle lines up with the slot in
the nut, insert the cotter pin (149).
If they do not line up, back off the nut until they
donot more than one additional flat.
Measure
Endplay in the hub/rotor should measure between

0.013-0.20 mm (0.0005-0.008 inches) when properly
adjusted.
4. Install the retainer/cap (148).
WHEEL HUB BOLT
Tools Required:
1. Hub/rotor assembly from the vehicle.
Refer to Wheel Hub/Rotor Assembly, in this
section.
NOTICE: Place J-9746-02 between the press
bars and the hub/rotor to protect the rotor
surfaces.
Support the hub/rotor (153) using J-9746-02 and
the press bars.
0
* tl
Install or Connect

of this section.
1. Wheel hub bolts (153) into the hub/rotor (154).
washers.
hub/rotor (154).
section.

ground.
STEERING ARM, KNUCKLE AND

SPINDLE
++

1. Caliper (142).
2. Hub/rotor assembly (154).
section.
3. Anchor plate (145), splash shield (141), and the
steering arm (140).
Bolts (146), washers (147) and nuts (129), and
pull the anchor plate and splash shield off the
knuckle. Steering arm hangs by tie rods.
Bolts (144) and washers (143) to separate the
anchor plate from the splash shield.
Refer to STEERING LINKAGE (SEC. 3B1) to
separate the steering arm from the tie rod and
pitman arm.
4. Caps (122) from the steering knuckle (127).
Brake hose bracket (121).
Gaskets (123) come off.
5. Lock pin (134).
6. King pin (124) from the steering knuckle (127).
Drive it out using a drift.
Spacers (126) and bushings (125) will also come
out.
7. Steering knuckle (127) from the axle (157).
Dust seal (130), shim (131), and thrust bearing
(137) will come free.
NOTICE: For steps 3, 4, and 5 refer to th e
1. Bushings (125).
Ream new b u s h in g s to 29.982-30.022m m
(1.1804-1.1820 in.) after installing.
2. Steering knuckle (127).
Thrust bearing (137), shim and the dust seal.
Prelube the thrust bearing. Refer to MAINTE
NANCE AND LUBRICATION (SEC. 0B).
3. King pin (124) and the lock pin (134).
Insert the spacers in the proper order.
Prelube the king pin.
Washer (133) and the nut (132).
Nut (132) to 40 N-m (29 ft. lbs.).

4. Caps (122) to the steering knuckle (127).

Gaskets (123) in place.
Brake hose bracket (121).
Washers (120) and bolts (119).
Tighten

5. Steering arm (140), splash shield (141), and the anchor
plate (145).
Bolts (144) and washers (143) to attach the
splash shield to the anchor plate.
Bolts (146), washers (147) and nuts (129) to
attach the anchor plate and steering arm to the
steering knuckle.
Tighten
6.
7.
8.
9.
10.
11.
Bolts (144) to 16 N-m (12 ft. lbs.).

Nuts (129) to 312 N-m (230 ft. lbs.).
Steering arm (140) to the steering linkage.
Hub/Rotor assembly (154).
section.
Adjust the wheel bearings.
section.
Caliper (142).
Wheel and tire assembly. Lower the vehicle to the
ground.
Check the front end alignment.
FRONT AXLE
++
1.
2.
3.
4.
5.
6.
7.

Tools Required:
stands on the frame. Remove the wheel and tire
assembly. Support the axle with a floor jack to
eliminate any load on the springs.
Steering arm, knuckle, and spindle.
Refer to Steering Arm, Knuckle, and Spindle,
in this section.
Shock absorber (113) from the axle (157) (figure 36).
Stabilizer link (116) from the stabilizer bar (166) (figure
37).
Use J-6627-A to separate the stabilizer bar from
the stabilizer link.
Stabilizer link (116) from the axle (157) (figure 37).
Nut (136), retainer (117) and insulator (118).
Pull the link free from the axle, making sure not
to loose the other insulator (118) and retainer
(117).
Leaf spring (162) from the axle (157) (figure 38).
Nuts (135), washers (105) and U-bolts (165).
Spacer (164), and spring spacer (158).
Steering damper from the axle.
Lower the floor jack and pull the axle clear of the
vehicle.

N o tice on page 3 C - 1 o f this section.
1. Line up the axle under the leaf springs.

Raise it into position using a floor jack.
2. Steering damper to the axle.
3. Axle (157) to the leaf springs (162).
Refer to Leaf Spring, in this section.
4. Stabilizer link (116) to the axle (157) (figure 37).
Link into the hole on the spring spacer (158) and
axle.
Insulator (118), retainer (117), and nut (136).
Tighten

37).
5. Stabilizer link to the stabilizer bar (166) (figure 37).
Tighten
Nut (115) to 68 N-m (50 ft. lbs.).
6 . Shock absorber (113) to the axle (157) (figure 36).
Tighten
Nut (109) to 50 N-m (37 ft. lbs.).
7. Steering arm, knuckle, and spindle.
Refer to Steering Arm, Knuckle, and Spindle,
in this section.
section.
ground.
Refer to FRONT END ALIGNMENT (SEC. 3B1).
LEAF SPRINGS
++
1.
2.
3.
4.

Tools Required:
stands. Support the axle separately to eliminate any
load on the springs. Remove the tire and wheel
assembly.
Shock absorber (113) from the axle (157) (figure 36).
Stabilizer link (116) from the stabilizer bar (166) (figure
37).
Use J-6627-A to separate the stabilizer bar from
the stabilizer link.
Stabilizer link (116) from the axle (157) (figure 37).
Nut (136), retainer (117), insulator (118).
Pull the link free from the axle, making sure not
to loose the other insulator (118) and retainer
(117).
Leaf spring (162) from the axle (157) (figure 38).
108
101.
105.
106.
107.
108.
135.
157.
158.
162.
165.
164.
173.
S p rin g H an g e r
W a sh er
B o lt
S h a ckle
N ut
N ut
F ro n t A xle
S p rin g S p a ce r
F ro n t S p rin g
U -B olt
S p a ce r
S p rin g H an g e r
135
B-07492
Figure 38Axle and Leaf Spring Attachment Points

Washer
(108) to
(173).
Washer
(108) to
(107).
Nuts (135), washers (105) and U-bolts (165).

Spacer (164) and spring spacer (158).
5. Leaf spring (162) from the frame (figure 38).
Nut (108), washer (105), bolt (106) and washer
(105) to separate the spring from the rear shackle
(107).
Nut (108), washer (105), bolt (106), and washer
(105) to separate the spring from the front hanger
(173).
Pull the leaf spring backward and out.
NOTICE: For steps 1, 2, 3, 4 and 5, refer to the
-+ Install or Connect (Figures 34 through 38).
1. Leaf spring (162) to the frame (figure 38).
Line up the spring with the rear shackle (107)
and the front hanger (173). Double wrap end is
toward the front of the vehicle.
(105), bolt (106), washer (105) and nut

attach the spring to the front hanger
(105), bolt (106), washer (105) and nut
attach the spring to the rear shackle
Tighten
Nut (108) to 125 N m (92 ft. lbs.).
2. Leaf spring (162) to the axle (157) (figure 38).

Position the spring spacer (158) onto the axle.
Either aligning pin can contact the edge of the
leaf spring after the assembly is complete.
Spacer (164), U-bolts (165), washers (105) and
nuts (135). Tighten nuts to 25 N-m (18 ft. lbs.) in a
diagonal sequence (e.g., 1-3-4-2).
Tighten
N uts (135) in a diagonal se qu en ce (e.g.,
1-3-4-2) to 109 N m (80 ft. lbs.).
3. Stabilizer link (116) to the axle (157) (figure 37).

Insert the link into the proper hole in the axle
after the retainer (117) and insulator (118) are
attached.
Insulator (118), retainer (117), and nut (136).
Tighten
Nut (115) to 68 N-m (50 ft. lbs.).
5. Shock absorber (113) to the axle (157) (figure 34).
Tighten
37).
4. Stabilizer link (116) to the stabilizer bar (166) (figure
37).
Nut (109) to 50 N-m (37 ft. lbs.).

ground.
Refer to FRONT END ALIGNMENT (SEC. 3B1).
ON-VEHICLE SERVICE:
FOUR WHEEL DRIVE FRONT SUSPENSION
SHOCK ABSORBER
STABILIZER BAR
|<~+| Remove or Disconnect (Figures 39 through 41)
|<~+| Remove or Disconnect (Figures 39, 40 and 42)

Nut (212), washer (213) and bolt (219) (figure 38).
2. Shock absorber (220) from the axle.
Nut (212), washer (213) and bolt (225).
Quad shocks (RPO Z75) have a spacer (246)
between them (figure 41).
Inspect
N O T IC E : For s te p s 1 a n d 2, re fe r to the
N o tice on page 3 C - 1 .

1. Shock absorber (220) to the axle.
Bolt (225), washer (213), and nut (212).
Spacer (246) must be positioned between the
shock absorbers (220) on vehicles with quad
shocks, RPO Z75 (figure 41).
Tighten
Nut (212) to 88 N-m (65 ft. lbs.).
Nut (212) to 120 N m (89 ft. lbs.) on quad
shocks (RPO Z75).
2. Shock absorber (220) to the frame.

Bolt (219), washer (213) and nut (212).
Tighten
Nut (212) to 88 N-m (65 ft. lbs.).
3. Lower the vehicle to the floor.

1. Stabilizer bar (230) from the frame brackets (237).
Nuts (231), washers (232), brackets (233), and
bolts (238) (figure 39).
2. Stabilizer bar (230) from the spring plate (224).
Bolts (229), and washers (228).
Stabilizer bar is free of the vehicle.
Bushings (234) can be removed from the
stabilizer bar.

1. Stabilizer bar (230) to the frame brackets (237).
Bushings (234) onto the stabilizer bar.
Use rubber lu b ric a n t when in s ta llin g the
bushings (slit faces forward) on the stabilizer bar.
Brackets (233), bolts (238), washers (232), and
nuts (231) (figure 39). Do not tighten.
NOTICE: Refer to N o tic e on page 3 C - 1 of
this section.
2. Stabilizer bar (230) to the spring plate (224).
Washers (228) and bolts (229) (figure 42).
Nuts (231) to 70 N-m (52 ft. lbs.).

Bolts (229) to 180 N-m (133 ft. lbs.).

|+ + | Remove or Disconnect (Figures 39, 40, and 43
through 45)
Tools Required:
J-68 93 -D W heel B e a rin g N ut W rench
(V10/1500-20/2500 Models)
J-23446 Torque Wrench Adapter
J-26878-A Wheel Bearing Nut Wrench (V30/3500
Models)

1. Caliper
2. Locking hub (249).
Refer to FRONT AXLE (SEC. 4C).
3. Locking nut (250), ring (251) and adjusting nut (252).
Use J-6893-D and J-23446 for V10/1500-20/2500
models.
Use J-26878-A for V30/3500 models.
4. Hub/Rotor Assembly (257).
Outer wheel bearing (253) will slide off the
spindle (265) ahed of the hub/rotor (257).
Use a brass drift and hammer for the seal (260)
and races (254, 258).
The inner bearing (259), race (258) are behind
the seal (260).
L*
Inspect
1. Rotor braking surfaces for scoring, pitting, or cracks.

2. Wheel bearings (253, 259) and races (254, 258).
section.
replace both.
Install or Connect (Figures 39, 40, and 43

through 45)
Tools Required:
J-6368 Bearing Race Installer (Outer)
J-23448 Bearing Race Installer (Inner)
J-68 93 -D W h e el B e a rin g N ut W rench
(V10/1500-20/2500 models)
J-26878-A Wheel Bearing Nut Wrench (V30/3500
models)
J-23446 Torque Wrench Adapter
1. Races (254, 258) into the rotor/hub (257).
Use J-8092 and J-6368 for installation of the
outer bearing outer race (254).
Use J-8092 and J-23448 for installation of the
inner bearing outer race (258).
Do not damage the hub/rotor during the race
installations.
Clean
Grease from the rotor/hub (257) and spindle (265).
Grease from the wheel bearings (253, 259).
bristles).
Do not spin the wheel bearings with compressed air
to dry them the wheel bearings may be damaged.
Im portant
Use an approved high-tem perature front wheel
bearing grease. Refer to M AIN TEN AN C E AND
LUBRICATION (SEC. 0B).
Do not mix greases as mixing may change the
greases properties resulting in poor performance.
2. Apply a thin film of grease to the spindle at the outer
wheel bearing seat and at the inner wheel bearing
seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each wheel

bearing cup, inside the rotor/hub (257).
4. Fill the wheel bearing (cone and roller assemblies) full
of grease.
Use a cone-type grease packer that forces
If a cone-type grease packer is not available,
pack the wheel bearings by hand.
If packing the wheel bearings by hand, work the
grease into the bearings between the rollers,
bearings (cones, rollers, and cage) with grease
and/or wear.
5. Inner wheel bearing (259) into the rotor/hub (257).
this wheel bearing.
6. New seal (260).
Use a flat plate to install the seal so it is flush
with the rotor/hub flange.
7. Rotor/hub (257).
Do not damage the spindle threads.
Press on the spindle until the wheel bearing fully
seats against the rotor/hub outer race.
9. Adjusting nut (252).
10. Adjust the wheel bearing.
section.
NOTICE: Refer to the N o tic e on page 3 C - 1
of this section.
11. Ring (251) and locking nut (250).
Tang on the inside diameter of the ring must
pass onto the slot on the spindle (265).
The hole in the ring must align with the pin on
the lock nut (250). Move the adjustment nut (252)
to align the pin.
Use J-6893-D or J-26878-A and J-23446.
Tighten
Lock nut (250) to 217 N m (160 ft. lbs.)
minimum.
12. Locking hub (249).
13. Caliper.
14. Wheel and tire. Lower the vehicle to the ground.
BEARING ADJUSTMENT
Im portant
ca nn ot be m ain ta in e d unless the fro n t w heel
bearings are correctly adjusted. The cones must be
a slip fit on the spindle and the inside diam eter of
the cones must be lubricated to insure the cones
w ill c re e p . T h e a d ju s tin g n u t m u s t h a ve a
free-running fit on the spindle threads.
248
209
210
211
208 214 215 216
203
232
/
231
246
B-07494
Figure 39V Model Front Suspension

201.
202.
203.
204.
205.
206.
207.
208.
209.
210.
211.
212.
213.
214.
215.
216.
217.
218.
219.
220.
221.
222.
223.
224.
225.
226.
227.
228.
229.
230.
B olt
Shackle
B ushing
N ut
W asher
Bracket
Bum per
Rivet
Nut
Bracket
B um per
Nut
W asher
Hanger
Rivet
Spacer
W asher
Nut
Bolt
S hock A bsorber
Leaf Spring
Nut
W asher
Plate
Bolt
Spacer
Bolt
W asher
Bolt
S tabilizer Shaft
231.
232.
233.
234.
235.
236.
237.
238.
239.
240.
241.
242.
243.
245.
246.
Nut
W asher
Bracket
Bushing
Rivet
Rivet
Bracket
Bolt
Nut
W asher
Hanger
Bolt
R einforcem ent
Bracket
Spacer
247. Bracket
248. Bolt
A. K3500 Series
Right Side
B. Quad S hock
RPO Z75
B-07495
Figure 40V Model Front Suspension
212
213
212
213
219
219
225
246
B
A.
B.
212.
213.
219.
220.
225.
246.
K Series Standard Shock A bsorber M ounting

K Series RPO Z75 Quad Shock A bsorber M ounting
Nut
W asher
B olt
S hock A bsorber
Bolt
Spacer
B-07493

Adjust
Raise the vehicle and support it with safety stands.
1. Remove the locking hub assembly (249), lock nut
250), and the ring (251).
Tighten
Adjusting nut (252) to 60 N m (50 ft. lbs.)
while rotating the hub/rotor in order to seat
the bearings.
2. Back off the adjusting nut (252) and retighten.
Tighten
For Automatic Hubs, torque the adjusting nut

to 47 N m (35 ft. lbs.) while rotating the wheel.
For Manual Hubs, torque the adjusting nut to
60 N m (50 ft. lbs.) while rotating the wheel.
3. Back off the adjusting nut (252).
For Autom atic hubs, back off 3/s of a turn
maximum.
For Manual hubs, back off enough to free the
bearing.
4. Ring (251) and lock nut (252).

Tang on the inside diameter of the ring must
pass onto the slot on the spindle (265).
The hole in the ring must align with the pin on
the lock nut (250). Move the adjustment nut (252)
to align the pin.
Tighten
Lock nut (250) to 217 N m (160 ft. lbs.)
minimum.
Measure
Endplay in the hub/rotor assembly. It should be set
between 0.025 to 0.254 mm (0.001 to 0.010-inch).
5. Locking hub assembly (249).
WHEEL HUB BOLT

Remove or Disconnect (Figures 39, 40, and
46)
Tools Required:
1. Hub/rotor assembly from the vehicle.
section.
Support the hub/rotor using J-9746-02 to prevent
damage to the rotor face (figure 46).

Tools Required:

this section.
1. New, serrated b olt (255) into the hole in the
hub/rotor.
washers (figure 47).
hub/rotor.
section.
SPINDLE
49)

249
B-07550
Figure 44Knuckle and Hub/Rotor Components (V30/3500 Models)
249.
250.
251.
252.
253.
254.
255.
257.
258.
259.
260.
261.
262.
Locking H ub A ssem bly

Locking Nut
Ring
A d ju s tin g Nut
O uter W heel Bearing
O ute r Race
W heel Hub Nut
R otor/H ub
Inner Race
Inner W heel Bearing
Seal
Nut
W asher
263.
264.
265.
266.
267.
268.
269.
270.
271.
272.
273.
274.
275.
Plate
Bracket
S pindle
Shaft Bearing
Bearing Seal
Spacer
Seal
Oil D eflector
Bolt
W asher
Cap
Steering K nuckle
Nut
276.
278.
279.
280.
281.
282.
283.
284.
285.
B olt
Bolt
King Pin
Seal
R etainer
Race
Bearing
Seal
Bearing Cap
and King Pin
286. B olt
287. B ushing
288. Spring
289.
290.
291.
292.
293.
294.
295.
296.
297.
298.
299.
300.
301.
G asket
S teering Arm
N ut
N ut
Lower Ball J o in t
Upper Ball J o in t
Nut
A dapter
Steering Arm
C o tte r Pin
Nut
A d ju s tin g Ring
R etainer
B-07464
Figure 45Knuckle and Hub/Rotor Components (V30/3500)

1. Wheel hub/rotor assembly.
section.
2. Spindle (265) from the steering knuckle (274).
Nuts (261) and plate (263) for V 10/1500-20/2500
models.
Nuts (261), washers (262), plate (263) and the
bracket (264) for V30/3500 models.
Tap the end of the spindle with a plastic or
rubber mallet to break it loose from the steering
knuckle (274) (figure 48).
A. W ashers
B. Nut
81. H ub/R otor
Figure 47Installing the Hub Bolts

NOTICE: The m achined surface of the spindle
must not be dam aged by vise jaws.
3. Spindle components.
Secure the spindle in a vise by locating on the
high step diameter.
A. Press Bars
B-07729
Figure 46Removing the Hub Bolts
Figure 48Removing the Spindle
A.
265.
267.
268.
269.
270.
2.54mm (0.10-inch) depth

S pindle
Bearing Seal
Spacer
Seal
Oil D eflector
B-07465
Figure 49Spindle Components

Bearing seal (267) and shaft bearing (266) (figure
49).
Spacer (268), seal (269), and oil deflector (270)
from the axle shaft (figure 49).
4. Spindle (265) onto the steering knuckle (274).

Slide the spindle over the axle shaft until it seats
on the steering knuckle. The bolts (278) must
protrude through the spindle.
Inspect
Spacer (268). Replace if it is worn.
Spindle (265) for any heat burns, scoring, or wear.
Replace if necessary.
1.
2.
3.
Tools Required:
J -2 3 4 4 5 -A
N ee dle
B e a rin g
In s ta lle r
(V10/1500-20/2500 models)
J-21465-17 Bearing Installer (V30/3500 models)
Relubricate the shaft bearing (266) and the spindle
(265) with a high melting point type wheel bearinq
g re a s e .
R e fe r
to
M A IN T E N A N C E
AND
LUBRICATION (SEC. 0B).
Shaft bearing (266) and bearing seal (267) into the
spindle (265) (figure 47).
For V10/1500-20/2500 models, use J-8092 and
J-23445-A.
For V 3 0 /3 5 0 0 m o d e ls, use J-80 92 and
J-21465-17.
Oil deflector (270) and seal (269) onto the axle shaft.
Seal (269) onto the oil deflector (270) with the
deflector lip toward the spindle (265).
Spacer (268) onto the axle shaft.
The chamfer points toward the oil deflector (270)
(figure 50).

this section.
5. Bracket (264) and plate (263).
Only the V30/3500 models use a bracket (264).
A. C ham fer Toward

The Seal
265. S pindle
268. Spacer
269. Seal
269
270. Oil D eflector
Figure 50Installing the Spindle
B-07454

Insert a wedge-shaped tool between the lower
ball joint (293) and the yoke. Tap on the tool to
release the knuckle assembly.
Insert the wedge-shaped tool between the upper
ball joint (294) and the yoke. Tap on the tool to
release the knuckle assembly.
NOTICE: For steps 2, 3, 4, 6 and 7, refer to
N otice on page 3C - 1 o f this section.
0
Figure 51Tightening the Adjusting Ring
Washers (262) (V30/3500 models only) and NEW
nuts (261).
Tools Required:
J-23447 Ball Stud Nut Wrench
Steering knuckle (274) to the axle yoke.
Ball joints (293, 294) into their respective sockets
in the axle yoke.
Finger tighten the nuts (292, 299) onto the ball
joints (293, 294). The nut with the cotter pin slot
goes with the upper ball joint.
2 . Push up on the steering knuckle [to keep the ball joint
(293) from turning in the knuckle] and partially torque
the lower ball joint nut (292).
Tighten
Tighten
Nuts (261) to 88 N m (65 ft. lbs.).
section.
7. Wheel and tire. Lower the vehicle to the ground.
STEERING KNUCKLE AND ARM

V10/1500-20/2500 MODELS (WITH BALL JOINTS)
51)
section.
3. Spindle (265) from the steering knuckle (274).
Refer to Spindle, in this section.
4. Tie rod from the steering arm (297).
5. Steering arm (297) from the steering knuckle (274).
Nuts (295) and adapters (296).
Discard the nuts (295).
NOTICE: Do not remove the adjusting ring (300)
unless new ball joints are being installed. If it is
necessary to loosen the ring to remove the
k n u c kle, do n ot loo sen it m o re than two
th re a d s . U se J -2 3 4 4 7 (fig u r e 5 1 ). The
nonhardened threads in the yoke can be easily
d am ag ed by the h a rd e n e d thread s in the
adjusting ring if caution is not used during
knuckle removal.
6. Steering knuckle (274) from the axle yoke.
Cotter pin (298), nuts (292, 299).
Nut (292) to 40 N-m (30 ft. lbs.)

3. Torque the adjusting ring (300).
Use J-23447 (figure 48).
^X
Tighten
Adjusting ring (300) to 70 N m (50 ft. lbs.

Torque the upper ball joint nut (299).
^X
Tighten
Nut (299) to 135 N m (100 ft. lbs.).

5. Cotter pin (298) into the nut (299).
Do not loosen the nut. Apply additional torque, if
necessary, to line up the hole in the ball joint with
the slot in the nut.
6. Apply the final torque to the lower ball joint nut (292).
Tighten
Nut (292) to 95 N m (70 ft. lbs.).
Steering arm (297) to the steering knuckle (274).
Adapters (296) and NEW nuts (295).
Tighten
Nuts (295) to 120 N m (90 ft. lbs.).
8 . Tie rod to the steering arm (297).

9. Spindle (265) to the steering knuckle (274).
section.
section.
13. Wheel and tire assembly.
Figure 52Removing the Cap and Steering Arm

Fasteners
V30/3500 MODELS (WITH KING PINS)
Remove or Disconnect (Figures 39, 40, and 5 2
through 5 5 )
1.
2.
3.
4.
Tools Required:
J-26871 King Pin Socket
Locking hub (249).
Wheel hub/rotor assembly.
section.
Spindle (265).
Upper cap (273) and/or steering arm (290).
For the cap, remove the bolts (271) and washers
(272) alternately as the compression spring will
force the cap up.
Figure 53Removing the Lower Bearing Cap and

King Pin
5.
6.
7.
8.
9.
10.
For the steering arm, remove the nuts (291)

alternately as the compression spring will force
the steering arm up (figure 52).
Gasket (289), and compression spring (288).
Discard the old gasket (289).
Lower bearing cap and king pin (285).
Bolts (271) and washers (272) (figure 53).
Upper king pin bushing (287).
Pull it out through the steering knuckle (274).
Steering knuckle (274) from the axle yoke.
Seal (301).
Upper king pin (279) from the axle yoke.
Use a large breaker bar and J-26871 (figure 54).
Apply 677-813 N m (500-600 ft. lbs.) of torque to
break the king pin free.
Retainer (281), race (282), bearing (283) and the seal
(284) from the axle yoke.
Punch all the components out at once (figure
55).
Discard the old seal (284).
If the retainer (281) is damaged, discard it.
Figure 55Removing the Retainer, Race, Bearing

and the Seal
NOTICE: For steps 4, 6, 7, refer to N otice on

page 3 C - 1 of this section.
|- n - | Install or Connect (Figures 4 0 , 41 and 56
through 58)
Tools Required:
J-7817 Front Pinion Bearing Installer
J-22301 King Pin Bearing Seal Installer
J-28871 King Pin Installer
1. Retainer (281) and the race (282).
Use a new retainer.
2. Fill the area in the retainer (281) and race with an
approved high temperature bearing lubricant. Grease
the bearing (282).
Use a cone-type grease packer that forces
If a cone-type grease packer is not available,
pack the bearing by hand. Work the grease
between the rollers, cones, and cage.
NOTICE: Failure to com pletely pack the bearing

(cones, rollers, and cage) with grease will result
in premature bearing damage and/or wear.
Refer to MAINTENANCE AND LUBRICATION
(SEC. OB).
3. Bearing (283) and seal (284).
Use J-22301 to install the NEW seal (Figure 57).
Do not distort the seal. It will protrude slightly
from the surface of the axle yoke flange when
fully seated.
4. Upper king pin (279).
Tighten
King pin (279) to 745 N m (550 ft. lbs.).

5. Steering knuckle (274) and bushing (287).
Felt seal (280) to the king pin (279) through the
steering knuckle.
Knuckle onto the king pin (279).
Place the bushing (287) over the king pin (279).
6. Bearing cap and king pin (285) to the steering knuckle
(278).
4 bolts (271) and washers (272).
Tighten
Bolts (271) alternately and evenly to 108 N-m
(80 ft. lbs.).
7. Steering arm (290) to the steering knuckle (274).
Com pression ring (288), gasket (289), and
steering arm (290).
Nuts (291).
Tighten
Nuts (291) alternately and evenly to 108 N-m

(80 ft. lbs.).
8. Spindle (265).
section.

J-6382-3 OR
J-23454-3
274
i)i
i'
293
mill)
J-23454-2
J-9519-10
274. Steering K nuckle
293. Lower Ball Jo in t
B-07510
Figure 61 Installing the Lower Ball Joint
11.
12.
13.
14.

section.
Locking hub (249).
Lower the vehicle to the ground.
BALL JOINTS (V10/1500-20/2500

MODELS ONLY)

60)
Tools Required:
J-23454-1 Lower Ball Joint Spacer
J-23454-3 or
J-6382 Upper Ball Joint Spacer
J-23454-4 Upper and Lower Ball Joint Sleeve
274
J-23454-1
J-6382-3 OR
J-23454-3
J-9519-10
A. Flat W asher
274. S teering K nuckle
B-07509
Figure 60Removing the Upper Ball Joint

section.
2. Spindle.
3. Steering knuckle (274) and steering arm (290).
Remove the steering arm (290) only if removing
the left axle yoke ball joints.
Refer to Steering Knuckle and Arm, in this
section.
> Place the steering knuckle in a vise (figure 59).
4. ' *er ball joint (293).
Must be removed before any service can be
done to the upper ball joint (294).
Snap ring from the lower ball joint (293).
Use J-9519-10, J-23 45 4-1, J-2 3 4 5 4 -4 or
equivalent (figure 59). Tighten until the ball joint
breaks free of the steering knuckle.
5. Upper ball joint (294).
Use J-9519-10, J-23454-3 (or J-6382-3) and
J-23454-4 (figure 60). Tighten until the ball joint
breaks free of the steering knuckle.
+- Install or Connect (Figures 39, 40, 61 and 62)
Tools Required:
J-23454-2 Upper and Lower Ball Joint Sleeve
J-23454-3 or
J-6382-3 Upper and Lower Ball Joint Spacer
1. Lower ball joint (293) into the steering knuckle (274).
The ball joint (no cotter pin hole in the threaded
end) must be positioned straight.
Use J-9519-10, J-23454-2, and J-23454-3 or
fully seats.
Snap ring in position.
2. Upper ball joint (294) into the steering knuckle (274).
Use J-9519-10, J-23454-2, and J-23454-3 or
fully seats.
3. Steering arm (290) and steering knuckle (274).

274
294
J-23454-2
J-6382
OR
J-23454-3
294. U p p e r Ball J o in t
B-07508
Figure 62Installing the Upper Ball Joint
4.
5.
6.
7.
8.
9.
Steering arm only if removed.

Refer to Steering Knuckle and Arm, in this
section.
Spindle (265).
Wheel hub/rotor assembly.
section.
Adjust the wheel bearings.
section.
Refer to FRONT END ALIGNMENT (SEC. 4C).
Lower the vehicle to the ground.
LEAF SPRING AND BUSHINGS

63)
Raise the vehicle on a hoist and support the front
axle with a floor jack. Raise the floor jack until all
tension is relieved from the springs.
1. Spring (221) from the frame.
Nut (218), washer (217), shackle (202), bolt (201),
bushings (203) and spacer (216) (figure 61).
2. Spring (221) from the hanger (241).
Nut (239), washers (240), and bolt (242) (figure
61).
3. Spring (221) from the axle.
For V 10/1500-20/2500 and the left side of
V30/3500 models, remove nuts (222), washers
(223), U-bolts (227), plate (224) and the spacers
(226).
For the right side of V30/3500 models, remove
the bolts (248), nuts (222), washers (223), U-bolt
(227), plate (224) and the spacers (226) (figure
63).
4. Shackle (202) from the spring (221).
Nut (218), washer (217), bolt (201), bushings
(203) and spacer (216) (figure 63).
5. Bushing from the spring eye.
Place the spring in a press and press out the

bushing using a suitable rod, pipe, or tool.
1. Bushing into the spring eye.

Press in a new bushing, making sure the tool
presses on the steel outer shell of the bushing.
Bushing must protrude an equal amount on
either side of the spring eye when properly
installed.
2. Shackle (202) into the spring (221).
Spacer (216), bushings (203), washers (217), bolt
(201) and nut (218).
Do not tighten.
3. Upper spacer (226) onto the spring (221).
4. Spring into the hanger (241).
Bolt (242), washers (240) and nut (239).
Do not tighten.
5. Spring into the frame.
Bushings (203) and the spacer (216) into the
frame.
Shackle (202) into position and attach bolt (201),
washer (217) and nut (218).
Do not tighten.
of this section.
6. Spring to the axle.
For V 10/1500-20/2500 models and the left side
of V30/3500 models, attach the lower spacer
(226), plate (224), U-bolts (227), washers (223)
and nuts (222) (figure 63).
For the right side of V30/3500 models, attach the
lower spacer (226), plate (224), U-bolt (227),
washers (223), bolts (248) and nuts (222) (figure
63).
Tighten
N uts (222) and b olts (248) in se q u e n c e
(2-4-1-3) to 203 N m (150 ft. lbs.) (figure 64).
6. Torque the spring to fram e and hanger fasteners.
Nuts (239) to 122 N m (90 ft. lbs.).
Nuts (218) to 68 N m (50 ft. lbs.).
7. Lower the floor jack, and lower the vehicle to the
ground.
218. N ut
221. Leaf S p rin g
B-07460
Figure 63Leaf Spring Attaching Parts
Figure 64U-Bolt Tightening Order
SPECIFICATIONS
ENDPLAY
R-G-P Models
0.03-0.13 mm (0.0012-0.005 inches)
V Models
0.025-0.25 mm (0.001-0.010 inches)
P Motorhome w/FS3
0.013-0.20 mm (0.0005-0.008 inches)
FASTENER TORQUE
IN D EP EN D E N T FR O N T SU S PEN SIO N
R a n d P M o d e ls
N -m
Shock Absorber to F ra m e ............................................................................. ........ 190
Shock Absorber to Lower Control A r m ....................................................... ........ 80
Stabilizer to F ra m e ................................................................................................... 33
Stabilizer to Lower Control A rm ............................................................................. 33
Steering Knuckle to Upper Ball Joint
R10/1500 ............................................................................................................ 68
All Other M o d e ls ...................................................................................... ........ 122
Steering Knuckle to Lower Ball J o in t .................................................................. 122
Ball Joint Cotter Pin Alignm ent
R10/1500 Upper Ball Joint M a x im u m ............................................ ........ 122
All Other Ball Joints M a x im u m ....................................................... ........ 176
Splash Shield to K nuckle........................................................................................ 13
Lower Control Arm Bushings (Exc. R 10/1500).......................................... ........ 379
Lower Pivot Shaft End Nuts (R10/1500 o n ly ) ............................................ ........ 95
Lower Pivot Shaft U-Bolt N u ts ............................................................................... 115
Upper Control Arm Bushings (Exc. R 10/1500).......................................... ........ 257
Upper Pivot Shaft End Nuts (R10/1500 o n ly ) ............................................ ........ 156
Upper Pivot Shaft Thru-Bolt Nuts
R 10/1500 ............................................................................................................ 95
All Other M o d e ls ...................................................................................... ........ 142
Upper Bolt Joint to Upper Control A rm ....................................................... ........ 25
Crossm em ber to Bottom Frame Rail
Motorhome................................................................................................. ........ 291
Van Models with JF 9 ............................................................................... ........ 176
All Other M o d e ls ...................................................................................... ........ 122
Crossmember to Frame Side Rails
P Models with J F 9 .......................................................................................... 135
All Other M o d e ls ...................................................................................... ........ 88
Suspension Bumper
R10/1500 M odels...................................................................................... ........ 20
All Other M o d e ls ...................................................................................... ........ 26
Crossmember to Support S tr u ts .................................................................. ........ 81
G M odels
Shock Absorber to Lower Control A r m ....................................................... ........ 103
Stabilizer to F ram e................................................................................................... 29
Stabilizer to Lower Control A rm ............................................................................. 33
Steering Knuckle to Upper Ball Joint
G 30/3500............................................................................................................ 122
All Other M o d e ls ...................................................................................... ........ 68
Steering Knuckle to Lower Ball J o in t ......................................................... ........ 122
Ball Joint Cotter Pin Alignm ent
G10/1500 and G20/2500 Models Upper Ball Joint Maximum . .
122
All Other Ball Joints M a x im u m ....................................................... ........ 176
F t. L b s .
140
59
24
24
50
90
90
90
130
10
280
70
85
190
115
70
105
18
215
130
90
100
65
15
19
60
80
80
21
24
90
50
90
90
130
G M odels (C ont.)
N-m
Splash Shield to K nuckle............................................................................... ........ 13
Lower Control Arm Bushings (G30/3500 o n ly ).......................................... ........ 379
Lower Pivot Shaft End Nuts (Exc. G 30/3500)............................................ ........ 156
Lower Pivot Shaft U-Bolt Nuts
G 30/3500................................................................................................... ........ 115
All Other M o d e ls ...................................................................................... ........ 88
Upper Control Arm Bushings (G30/3500 o n ly ).......................................... ........ 258
Upper Pivot Shaft End Nuts (Exc. G 30/3500)............................................ ........ 156
Upper Pivot Shaft Thru-Bolt Nuts
G30/3500 M o d e ls ............................................................................................ 142
All Other M o d e ls ...................................................................................... ........ 95
Upper Bolt Joint to Upper Control A rm ....................................................... ........ 25
Crossmember to Bottom Frame R a il........................................................... ........ 122
Crossmember to Side Frame R a il........................................................................ 88
Suspension B um per........................................................................................ ........ 20
Crossmember to Support S tru ts .............................................................. .
81
Ft. Lbs.
10
280
115
85
65
190
115
105
70
18
90
65
15
60
I-BE AM (RPO FS3) FR O N T SU S PEN SIO N

P30 M odels
Shock Absorber to A x le .......................................................................................... 50
Stabilizer to F ra m e .......................................................................................... ........ 29
Stabilizer to Stabilizer L in k ........................................................................... ........ 68
Splash Shield to Anchor Plate............................................................................... 16
Steering Arm to K n u c k le ............................................................................... ........ 312
Caps to Steering K n u c k le ............................................................................. ........ 7
Lock Pin to Steering K n u c k le ............................................................................... 40
Spring to Hanger N u ts ............................................................................................ 125
Spring to Shackle N u t s .......................................................................................... 125
Spring to Axle U-Bolt N uts............................................................................. ........ 109
Shackle to Frame N u t s .......................................................................................... 125
136
37
21
50
12
230
5
29
92
92
80
92
25
FOUR W H E EL DRIVE FR O N T SU S PEN SIO N

V M odels
Shock Absorber to A x le .......................................................................................... 88
Stabilizer to Frame
V 3 0 /3 5 0 0 ................................................................................................... ........ 70
All Other M o d e ls ...................................................................................... ........ 95
Stabilizer to Spring P la te ............................................................................... ........ 180
Steering Knuckle to Upper Ball Joint (Exc. V30/3500)..................................... 135
Steering Knuckle to Lower Ball Joint (Exc. V30/3500)..................................... 40
Ball Joint Cotter Pint Alignm ent (Exc. V30/3500)
Upper Ball Joint M a x im u m ...................................................................... 176
Adjusting Ring to Spindle (Exc. V30/3500)......................................................... 70
Caps to Steering Knuckle (V30/3500 o n ly )......................................................... 108
King Pin to Knuckle (V30/3500 only).................................................................... 745
Anchor Plate to K n u c k le ............................................................................... ........ 88
Steering Arm to K n u c k le ............................................................................... ........ 120
Lock Pin to Steering K n u c k le ............................................................................... 217
Spring to Hanger N u ts ............................................................................................ 122
Spring to Shackle N u t s .......................................................................................... 68
Spring to Axle U-Bolt N uts............................................................................. ........ 203
Shackle to Frame N u t s ................................................................................. ........ 68
65
65
52
70
133
100
30
130
50
80
550
65
90
160
90
50
150
50
15
SPECIAL TOOLS
1.
J-24435-A
2.
J-23448
9.
J-9519-D
10.
J-23742
J-22301
12
J-21365-17
13.
J-8092
14.
J-23447
15.
J-9746-02
16.
J-23028-01
J-23454-D
3.
11
4.
5,
J-6368
6.
7.
8.
1.
2.
3.
4.
5.
6.
7.
8.
J-26878-A
J-7817
J-6893-D
J-6627-A
Needle Bearing In sta lle r

Inner Bearing Race In sta lle r
Ball J o in t Remover and Installer
W heel Bearing N ut W rench
O uter Bearing Race In stalle r
Front Pinion Bearing In sta ller
W heel Stud and Tie Rod Remover
9.
10.
11.
12.
13.
14.
15.
16.
Ball Jo in t Remover and In staller

Ball Jo in t Separator
King Pin Bearing Seal In staller
Bearing In staller
Driver Handle
Ball Stud N ut W rench
H ub/R otor S upport
Spring Remover
Tools Not Shown

A. J-8457
B. J-8849
C. J-29040
W heel Bearing Race In staller

W heel Bearing Race In sta lle r
Outer Bearing Race In staller
D. J-23446
E. J-28871
F. J-22717
Torque W rench A dapter

King Pin In sta lle r
Lower C ontrol Arm B ushing Stake Remover
B-07725
REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
The following Notice applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the term inology Notice: Refer to the Notice on page 3D-1 of
this section.
NOTICE: Theserearsuspension fastenersareimportant attachingparts in that theycouldaffect theperform

anceof vital parts andsystems, and/or couldresult in major repair expense. Theymust bereplacedwith one
of thesamepart number or withanequivalent part if replacement becomesnecessary. Donot useareplace
ment part of lesser quality or substitute design. Torque valuesmust beusedasspecifiedduring reassembly
to assureproper retention of theseparts.
CONTENTS
SUBJECT
PAGE
General D e scrip tio n ....................................................................................................................................................3D - 1

On Vehicle S e r v ic e ....................................................................................................................................................3D - 8
Shock Absorber Replacem ent.............................................................................................................................. 3D - 8
Stabilizer Bar R eplacem ent...................................................................................................................................3D - 8
Leaf Spring Assem bly Replacem ent.................................................... ...............................................................3D - 9
Bushing R e p lace m e n t........................................................................................................................................... 3D-10
S pecifica tio ns...............................................................................................................................................................3D -12
GENERAL DESCRIPTION
All 10/1500 through 30/3500 series vehicles use a leaf
spring and solid rear axle suspension system (figures 1
through 7).
The rear axle assembly is attached to multi-leaf springs
by U-bolts. The front ends of the springs are attached to
the frame at the front hangers, through rubber bushings.
The rear ends of the springs are attached to the frame by

the use of shackles which allow the springs to change
their length while the vehicle is in motion.
Ride control is provided by two identical direct double
acting shock absorbers angle-m ounted between the
frame and brackets attached to the axle tubes.
3D-2 REAR SUSPENSION
Figure 1Rear Suspension (R/V 10/1500, 20/2500 Pickup, Suburban, and Blazer/Jimmy)
Figure 2Rear Suspension (R/V 30/3500 Series Vehicles)
Figure 3Rear Suspension (G 10/1500-30/3500 Series Vehicles)
Figure 4Rear Suspension (G30/3500 Series Cutaway Van with RPO M40)
Figure 5Rear Suspension (P20/2500 Series Vehicles)
Figure 6Rear Suspension (P30/3500 Series Vehicles)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
B ra cke t
B o lt
W a sh e r
R ear H a n g e r
N ut
R ear S h a c k le
A n c h o r P late
U -b olt
S h im
Leaf S p rin g
N ut
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
S p rin g L ock W a sh er
R ear S h o c k A b s o rb e r
B o lt
S p rin g L o ck W a sh er
N ut
F ro n t H a n g e r S u p p o rt
F ro n t H a n g e r
A x le B u m p e r
B u m p e r B ra cket
W a sh e r
N ut
23. B ra cket
24. C u s h io n
25. Rear H a n g e r
26. Leaf S p rin g Eye
B u s h in g
27. B o lt
28. N ut
29. N ut
30. B o lt
31. S p a ce r
Figure 7Rear Suspension Legend
32. O p tio n a l Rear

A u x ilia ry S p rin g
33. B o lt
34. W a sh er
35. N ut
36. S ta b iliz e r Bar
Anchor
37. S p a c e r
38. B o lt
39. S p rin g C lip
B-07521
ON-VEHICLE SERVICE
SHOCK ABSORBER
REPLACEMENT
For R/V and P series ve hicles; nut (16),
spring-washer (15), and/or washer (21).
For G series vehicles; nut (16), spring washer
(15), washer (3), and bolt (38).
2. Shock absorber (13) from the axle.
Nut (11), spring-washer (12), and bolt (14).
Pull the shock absorber free.

N O T IC E : For s te p s 1 a n d 2, re fe r to the
N o tice on page 3D-1 of this section.
1. Shock absorber (13) to the frame.

For R/V and P series vehicles; spring-washer
(15) and/or washer (21), plus the nut (16).
For G series vehicles; bolt (38), washer (3),
spring-washer (15), and nut (16).
Tighten
Nuts (16) to Specifications at the end of this
section.
Shock absorber (13) to the axle.
Line shock absorber up with the axle bracket.
Bolt (14), spring-washer (12), and nut (11).
St
Tighten
For all R/V and P series vehicles; nut (11) to

155 N m (114 ft. lbs.).
For all G series vehicles; nut (11) to 102 N-m
(75 ft. lbs.).
Figure 8Rear Stabilizer A ttachm ents

(R30/3500 Series Vehicles)
STABILIZER BAR REPLACEMENT

Remove or Disconnect (Figures 8, 9, and 10)
1. Stabilizer bar (108) from the frame.
For R 30/3500 series vehicles; nut (120), and
washer (116). Slide the link bolt (115) out along
with the grommets (117), washers (116), and
link (118).
For P 30/3500 series vehicles; nuts (105),
washers (106), bolts (111), and the clamp (110).
2. Stabilizer bar (108) from the anchor plates (107).
Nuts (105), washers (106), bolts (111), and the
clam ps (110).
3. Insulators (109) from the stabilizer bar (108).
N O T IC E : For s tep s 2 a n d 3, r e fe r to the

N o tice on page 3D-1 of this section.
1. Insulators (109) to the stabilizer bar (108).
2. Stabilizer bar (108) to the anchor plates (107).
Clamps (110), bolts (111), washers (106), and
nuts (105).
Tighten
Refer to Specifications at the end of this
section.
Im portant
Route the parking brake cable over the stabilizer
bar.
3. Stabilizer bar (108) to the frame.
For the R 30/3500 series vehicles; position the

link bolt (115), washers (116), grommets (117),
link (118), retainer (119) and nut (120).
For the P 30/3500 series vehicles; attach the
clamp (110), bolts (111), washers (106), and
nuts (105) in position.
Tighten
Nuts (120 and 105) to the Specifications at
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
U -b olt
S p a ce r
S p rin g S p a ce r
A n c h o r Plate
N ut
S p rin g L ock W a sh er
S ta b iliz e r Bar A n c h o r
S ta b iliz e r Bar
B u s h in g
B ra cket
B o lt
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
N ut
W a sh er
S p ace r
B o lt
W a sh er
G ro m m e t
L in k
R e ta in e r
N ut
B ra cket
B-07524
LEAF SPRING ASSEMBLY

REPLACEMENT
Raise the vehicle on a hoist and support the rear
axle independently to relieve tension on the leaf
springs.
1. Stabilizer bar from the vehicle if equipped.
Refer to Stabilizer Bar Replacement, in this
section.
2. Leaf spring (10) from the rear hanger (25).
Loosen,
but
do
n ot
re m o v e ,
th e
spring-to-shackle nut and bolt.
Nut and the bolt securing the shackle to the
rear hanger (25).
3. Leaf spring (10) from the front hanger (18).
Nut and the bolt securing the leaf spring (10)
to the front hanger (18).
4. Shackle (6) from the leaf spring (10).
Nut and bolt securing the shackle to the leaf
spring.
5. Leaf spring from the axle.
Nuts (22), and washers (21).
Rear stabilizer anchor (36) if equipped, the
anchor plate, spacers, shims, and the auxiliary
spring (32), if equipped.
U-bolts (8).
Figure 10Rear Stabilizer Attachments Legend
Leaf spring is free of the vehicle.

11)
N O T IC E : For s tep s 1 and 4, re fe r to the
N o tice on page 3D-1 o f this section.
1. Leaf spring (10) to the rear axle.
Leaf spring into position.
Spacers, shims, the auxiliary spring (32) if
equipped, and the anchor plate.
Tighten
Nuts (5) and bolts (2), to the Specifications at the

5. Stabilizer bar to the vehicle if equipped.
Refer to Stabilizer Bar R eplacem ent, in this
section.
6. Lower the support on the rear axle. Lower the
vehicle to the ground.
BUSHING REPLACEMENT
Tighten
Nuts (22), in a diagonal sequence as shown in
figure 11, initially to 25 N m (18 ft. lbs.). Then
final torque in a diagonal sequence as shown
in figure 11 to the Specifications at the end
of this section.
2. Shackle (6) to the leaf spring (10).
Bolt (2), washers (3), and nuts (5), making sure
the bolt is positioned correctly (figures 1
through 7).
Do not tighten.
3. Leaf spring to the front hanger (18).
Bolt (2), washers (3), and nut (5).
Do not tighten.
4. Leaf spring to the rear hanger (25).
Bolt (2), washers (3), and nut (5).
PRESS OUT TYPE BUSHINGS

1. Leaf spring (10) from the vehicle.
R e fe r
to
Leaf
S p rin g
R eplacem ent, in this section.
A s s e m b ly
2. Bushing from the leaf spring (10).

Place the leaf spring in a press and press out
the bushing.

1. Bushing into the leaf spring (10).
Use a press to properly position the bushings.
2. Leaf spring (10) to the vehicle.
R e fe r
to
Leaf
S p rin g
Replacem ent, in this section.
A s s e m b ly

PRY OUT TYPE BUSHINGS
|+ + | Rem ove o r D is c o n n e c t (F ig u re s 2 and 4
through 7)
1. Leaf spring (10) from the vehicle.
R e fe r
to
Leaf
S p rin g
A s s e m b ly
2. Bushings (26) from the leaf spring (10).
Pry the bushings out of each side of the spring
eye.
|-+| Install or Connect (Figures 2 and 4 through 7)

1. Bushings (26) into the leaf spring (10).
Press each bushing (26) into its side of the
spring eye.
2. Leaf spring (10) onto the vehicle.
R e fe r
to
Leaf
S p rin g
A s s e m b ly
SPECIFICATIONS
FASTENER NAME
TORQUE N m (FT. LBS.)

R10/15
R20/25
R30/35
V10/15
V20/25
V30/35
G10/15
G20/25
G30/35
P20/25
P30/35
70 (52)
102 (75)
102 (75)
102 (75)
33 (24)
70 (52)
102 (75)
102 (75)
102 (75)
155 (114)
155 (114)
Shock Absorber To Frame Nut
190 (140) *190 (140)
Shock Absorber To Axle Nut
155 (114) *155 (114) 155 (114) 155 (114) 155 (114) 155 (114)
70 (52)
190 (140) 190 (140)
Stabilizer Bar To Frame Nut
**
Stabilizer Bar To Anchor Nut
33 (24)
Stabilizer Bar Bracket To Hanger
Stabilizer Bar Bracket To Frame
29 (21)
29 (21)
33 (24)
33 (24)
Anchor Plate To U-bolt Nut

(U-bolts Facing Up)
170 (125) 170 (125) 170 (125) 170 (125) 170 (125) 170 (125) 155 (114) 155 (114) 205 (151) 170 (125)
Anchor Plate to U-bolt Nut

(U-bolts Facing Down)
200 (147) 200 (147) 200 (147) 200 (147) 200 (147) 200 (147)
205 (151)
***200 (147)
Spring To Hanger Nut
125 (92)
Spring To Hanger Bolt
150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 185 (136) 185 (136) 185 (136) 150 (110)
150 (110)
Spring To Shackle Nut
125 (92)
125 (92)
125 (92)
Spring To Shackle Bolt
150 (110) 150(110) 150 (110) 150 (110) 150 (110) 150(110) 185 (136) 185 (136) 185 (136) 150 (110)
150 (110)
Shackle To Hanger Nut
125 (92)
125 (92)
125 (92)
Shackle To Hanger Bolt
150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 185 (136) 185 (136) 185 (136) 150 (110)
150 (110)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
N/A
125 (92)
125 (92)
N/A
125 (92)
125 (92)
N/A
125 (92)
N/A
For M odels w ith RPO JF9 o r P318(32) Torque Spring to Hanger B olt to 200 N m (147 ft. lbs.) and Tighten Shcakle Fasteners to 135 N m (99 ft. lbs ).
Crew Cab M odel Torque is 70 N m (52 ft. lbs.) fo r Shock to Frame, and 155 N m (114 ft. lbs.) fo r S hock to Axle.
* * Tighten The N ut To The Unthreaded Portion Of The Link Bolt.

* * * Torque Is 240 N m (177 Ft. Lbs.) W hen Equipped W ith RPO JF9.
WHEELS AND TIRES 3E-1
SECTION 3E
W HEELS AND TIR ES

CONTENTS
SUBJECT
PAGE
General Description.......................................................................................................................................................3E- 1
Certification L a b e l.................................................................................................................................................... 3E- 1
Tire Load Limits And Inflation P re ssure ............................................................................................................... 3E- 1
Diagnosis Of Wheels And T ire s ..................................................................................................................................3E- 3
Checking Wheel And Tire R u n o u t......................................................................................................................... 3E- 3
On-Vehicle S e rv ic e ...................................................................................................................................................... 3E- 4
Measuring Wheel And Tire Runout..........................................................................................................................3E- 4
Excessively Tight W heels........................................................................................................................................ 3E- 5
Separating The Tire From The W h e e l................................................................................................................... 3E- 6
Mounting The Tire On The W h e e l..........................................................................................................................3E- 6
Installing The Wheel And Tire Assembly............................................................................................................... 3E- 7
Aluminum Wheel R e fin ishing ..................................................................................................................................3E- 8
Wheel And Tire Balancing........................................................................................................................................ 3E- 8
Optional Spare Tire C arriers....................................................................................................................................3E- 8
Specifications.................................................................................................................................................................3E-11
Wheel Runout.............................................................................................................................................................3E-11
Wheel Stud Nut Torque (Single Front And Rear W h e e ls).................................................................................. 3E-11
Wheel Stud Nut Torque (Single Front And Dual Rear W heels).......................................................................... 3E-11
Tire Load Limits And Inflation P ressure............................................................................................................... 3E-12
Wheel Codes And Load L im its ................................................................................................................................3E-12
GENERAL DESCRIPTION
This section details special service procedures that are
not covered in the vehicles O wners Manual. For jacking
instructions, basic tire changing and rotation instructions,
and a detailed explanation of all other owner-oriented in
formation, refer to the proper section in the vehicles Own
e rs Manual.
CERTIFICATION LABEL
The certification label contains information used to
determine which tire size and type the vehicle uses. For
further information, refer to GENERAL INFORMATION
(SEC. OA).
TIRE LOAD LIMITS AND

INFLATION PRESSURE
The factory installed wheels and tires are designed to
handle loads up to and including their rated load capacity
when inflated to the recommended inflation pressures.
Refer to Tire Load Limits And Inflation Pressure at the
Correct tire pressures and driving techniques influence

tire life. Underinflated tires can cause handling problems,
p o o r fu e l e co n o m y , s h o rte n e d tire life , and tire
o v e rlo a d in g . H ea vy c o rn e rin g , e x c e s s iv e ly ra p id
acceleration, and unnecessary braking also increase tire
wear.
| 9 | Im p o rta n t
The use of wheels and/or tires with higher load
capacity ratings than originally equipped on the
vehicle will not increase the Gross Axle Weight
Rating (GAWR) or Gross Vehicle Weight Rating
(GVWR) of the vehicle.
3E-2 WHEELS AND TIRES
B-07463
Figure 1Radial Tire Lead/Pull Disgnosis Chart
DIAGNOSIS OF WHEELS AND TIRES

The following information (including figure 1) will help to identify certain tire-related durability and drivability problems.
Excessive Heel And

Toe Wear
Excessive Tire
Edge(s) Wear
CORRECTION
POSSIBLE CAUSE
PROBLEM
1. Inflate to recommended pressure.

2. Correct as required refer to certifica
tion label.
3. Correct as required.
4. Set to correct specifications.
1. Underinflated tires.
2. Vehicle overloaded.
3. High speed cornering.
4. Incorrect toe setting.
Excessive Tire Wear

(Center Of Tread)
Uneven Tire Wear
Deflate to recommended pressure.
Overinflated tires.
1.
2.
3.
4.
5.
Im proper tire pressure.

Incorrect tire and wheel usage.
Worn shock absorbers.
Front end out of alignment.
Loose, worn, or damaged steering link
age, joints, suspension com ponents,
bushings and/or ball joints.
6. Out of balance wheel/tire.
Radial Tire Waddle

(Side To Side
Movement At Speeds
Between 5 and 15
MPH)
Vibration
Correct as required, rotate tires regu

larly.
High speed driving, excessive use of

brakes.
1.
2.
3.
4.
5.
6. Balance wheel/tire.
Replace worn tires.
Worn tires.
1.
2.
3.
4.
Out of balance wheel/tire.

Tire runout.
Wheel runout.
Worn tire.
CHECKING WHEEL AND

TIRE RUNOUT
Some vehicles are sensitive to tire and wheel assembly
runout. Tires that are satisfactory on one vehicle might be
unsatisfactory on another. W hen analyzing vibration
problems, it is important to keep this in mind. In addition,
different wheel positions on a vehicle may have different
sensitivity levels. You should check for wheel runout or
total wheel and tire runout in the following cases:
Inflate to recommended pressure.

Install correct tire-wheel combination.
Replace shock absorbers.
Align the front end.
Inspect, repair or replace as required.
1.
2.
3.
4.
Balance
Replace
Replace
Replace
wheel/tire.
tire.
wheel.
tire.
If the tire and wheel vibration occurs below 40 miles

per hour.
If all wheels are balanced well within one ounce of
static balance and five ounces of dynamic balance,
and a vibration occurs.
If there appears to be a bulge in a tire or an
out-of-round condition as a tire rotates on a balancer.
If any wheel damage is noticed.
If there is a poor wheel fit on the hub and the vehicle
exhibits vibration.
ON-VEHICLE SERVICE
Figure 2Measuring Radial Runout
MEASURING WHEEL AND

TIRE RUNOUT
Runout measurements of the wheel and tire assembly
can be taken both on and o ff th e ve h ic le . These
measurements can be taken radially and laterally. A dial
indicator equipped with a roller contact point, mounted on
a heavy, solid base is the measurement device.
RADIAL RUNOUT
Radial runout is the egg-shaped difference from a
perfect circle. Measure tire radial runout from the center
tire tread rib although other tread ribs can be measured
as well. The total runout is the reading from the gage, and
the high spot is the location of the maximum runout. On a
rim, if either flange is beyond specifications, replace the
rim (figure 2).
LATERAL RUNOUT
Lateral runout is a sideways variation causing a twist or
wobble and is measured on a side surface. On the tire
and wheel assembly, measure the sidewall of the tire as
close to the trend shoulder design edge as possible. The
total runout is the reading from the gage, and the high
spot is the location of the maximum runout. On a rim, if
either flange is beyond guidelines, replace the rim (figure
3).
MEASUREMENT PROCEDURES
Inflate the tires to specifications.
Warm up the tires prior to taking measurements to
eliminate flat spotting.
Newly installed tires usually do not require
warming up.
3. Raise the vehicle on a lift.
If measurements will be taken off the vehicle,
mount each tire and wheel assembly on a
dynamic balance machine.
Mark the tire and w heel a ssem blies for exact
replacement.
Mark a wheel hub bolt and its exact position on
the wheel.
A.
B.
C.
D.
T ire H ig h S p o t
W h e e l H ig h S p o t
W h e e l Low S p o t
T ire Low S p o t
1. Dial In d ic a to r
B-07451
Figure 3Measuring Lateral Runout

M ark each tire and w heel a s s e m b ly fo r
replacement on the exact hub/rotor assembly.
5. Take either a radial or lateral runout measurement.
Place the dial indicator in position.
Rotate the tire and wheel assembly (or just the
wheel) to find its low spot. Adjust the dial
indicator to read zero.
Rotate again to verify the low spot locationthe
dial indicator must return to zero.
Disregard any instantaneous dial jumps due to
welds, paint runs, scratches, etc. on the wheel.
Rotate the tire and wheel assembly (or just the
wheel) and note the amount of variance (runout)
from zero. Locate and mark the high spot.
6. If there is a large difference in runout measurements
from ON vehicle to OFF vehicle, the runout problem is
likely due to excessive runout of the bolt circle or hub.
7. If measured runouts are not within the guidelines
(located in Wheel Runout Specifications at the end
of this section), proceed to Vectoring to correct the
problem.
VECTORING
Vectoring is a technique used to reduce radial or lateral
runout and even dynamic balance on tire and wheel
a s s e m b lie s . V e c to rin g c a n be a c c o m p lis h e d by
positioning of the tire on the wheel and positioning of the
tire and wheel assembly on the hub/rotor.

B
2.
3.
A.
B.
C.
D.
E.
T ire
T ire R eferen ce M ark A t 12 O c lo c k
F irs t M e a su re m e n t (H ig h S p ot)
Valve S tem A t 12 O c lo c k
S e co n d M e a su re m e n t (H ig h S pot)
T ire R eference M ark A t 6 O c lo c k
B-07455
Valve S tem and T ire R eferen ce M ark

at 12 O c lo c k
F irs t M e a s u re m e n t (H ig h Spot)
Valve S tem at 12 O c lo c k
S e con d M e a s u re m e n t (H ig h Spot)
T ire R eferen ce M ark at 6 O c lo c k
F-02342
Figure 4 Checking Tire to Wheel Vectoring
Figure 5Tire to Wheel VectoringExcessive Runout
| j I Important
Tire And Wheel Assembly To Hub/Rotor Vectoring
Always rebalance the tire and wheel assembly

after vectoring.
Tire To Wheel Vectoring

1. Determine which runout needs to be minimized.
Determine visually.
2. If radial runout is the problem, take a measurement on
the center tread rib.
If the trend is uneven, wrap tape tightly around
the tire, record the runout magnitude, and mark
the high spot location (figure 4).
3. If lateral runout is the problem, take a measurement on
the sidewall just below the edge of the tread shoulder.
Record the runout magnitude, and mark the high
spot location.
4. Mark the tire sidewall at the valve location.

This is the 12 oclock position.
The location of the high spot is always with
respect to the clock location on the wheel.
5. Break the tire and wheel assembly down on a tire
mounting machine and rotate the tire 6 hours (180) on
the rim (figure 4).
Reinflate the tire and measure the runout in
question.
Record the magnitude and the location of the
high spot. (Valve stem is 12 oclock.)
1. Mark the wheel hub bolt nearest the valve stem for
reference (figure 6).
2. Rotate the assembly two wheel hub bolts and recheck
the runout (figure 6).
Several positions may have to be tried to locate
the optimum location.
This can be effective for both radial and lateral
runouts.
3. If there is some looseness in the wheel hub bolt holes,
radial runout can be reduced by loosening the hub bolt
nuts slightly, moving the wheel position on the bolts
and then retightening the nuts.
4. Balance the tire and wheel to hub/rotor assembly.
Compensates for any imbalance in the brake
rotor, drum, or wheel cover.
EXCESSIVELY TIGHT WHEELS

Use this procedure to remove the wheel and tire
assembly if it does not break free of the hub using a
standard removal procedure.
1. Tighten all the lug nuts on the affected wheel.
Do not torque.
2. Raise the vehicle.
6. If the clock location of the high spot remained at or

near the clock location of the original high spot, the rim
is the major contributor to the runout problem.
Confirm by removing the tire from the wheel and
check the wheel rim runout.
If the wheel rim runout exceeds guidelines,
replace the wheel.
7. If the clock position of the high spot is 6 hours from the
original high spot, the tire is the major contributor to
the runout problem (figure 5).
Replace the tire.
8. After correcting the tire to the wheel vectoring,
rebalance the wheel and tire assembly.
Figure 6Tire and Wheel Assembly to Hub/Rotor

Vectoring

3. Loosen each nut two turns.
4. Lower the vehicle to the floor.
5. Rock the vehicle from side to side to loosen the wheel.
Or rock the vehicle from forward to reverse allowing the
vehicle to move several feet in each direction. Apply
quick, hard jabs on the brake pedal to loosen the
wheel.
6. Raise the vehicle and remove the lug nuts and the
wheel.
SEPARATING THE TIRE

FROM THE WHEEL
N O TIC E: Use a tire c h a n g in g m a c h in e to
demount tires. Do not use hand tools or tire
irons alone to remove the tire from the wheel.
Damage to the tire beads or wheel rim could
result.
Follow the tire changing machine m anufacturers
instructions to properly separate the tire from the
wheel.
MOUNTING THE TIRE ON

THE WHEEL
BIAS PLY TIRES
1. Clean the tire bead area.
RADIAL PLY TIRES

NOTICE: Recomm ended vehicle tire mounting
a n d in fla tio n p ro c e d u re s a re e s p e c ia lly
im portant with radial tires. Failure to follow
these procedures can cause bead deformation
in both tube type and tubeless tires due to
incorrect bead seating. Bead deformation may
lead to chafing, lower sidewall and bead area
cracking, eccentric wear, ride vibration and
nonretreadable castings.
Tube Type Tires

| 9 | Im portant
Only use rims approved for radial tire usage by the
rim manufacturer.
1. Clean the rim parts.
Remove all rust and other foreign material.
Make sure the rim parts match and are not
sprung or broken.
2. Lubricate the tire beads, the portion of the tube
between the beads, and the flaps with an approved
rubber lubricant.
Radial tubes are identifiable by the letter R in
the size designation. A red band in the valve
stem and an R in the flap size designation also
identify radial parts.
N O T IC E :
Do
not
u se
s ilic o n e
b as e
lubricants this could cause the tire to slip on
the wheel.
2. Clean the rim bead seats with a wire brush or coarse

steel wool to remove lubricants, old rubber, and light
rust.
3. Inflate to operating pressure, deflate completely, and

reinflate to operating pressure.
3. Apply an approved tire lubricant to the tire bead area.
Allows the tube, flap, and tire to fit together
4. Attach the tire to the wheel.

Use a tire ch an ging m achine. Follow the
equipment manufacturers instructions.
CAUTION: Do not stand over tire when inflating.
The bead may break when it snaps over the
safety hump, and cause serious personal injury.
Do not exceed 275 kPa (40 psi) pressure when
inflating. If 275 kPa (40 psi) pressure will not
seat beads, deflate, re-lubricate and reinflate.
Overinflation may cause the bead to break and
result in personal injury.
5. Install a valve core and inflate to the specified pressure
(figure 2).
The locating rings on each side of the tire must
show above the rim flanges, positioned in direct
relation to the wheel (not eccentric as compared
with the rim).
6. Check the bead seating.
T ire s m ust be m ounted and in fla te d in
accordance with the safety precautions included
with the tire mounting equipment.
p r o p e r ly .
4. Check the bead seating.

Visually check the slot and side ring gap (on two
piece rims) to make sure the bead is seated.
5. Check the spacing between the rim flange and one of
the three lower sidewall rim line rings while the tire is
laying flat to verify bead seating.
Measurements must be taken each 90 degrees
around the circumference of the rim flange.
If the spacing is uneven around the bead from
side to side, repeat steps 1 through 3, then
recheck.
Installing Synthetic Tubes

NOTICE: When the tube and the flap are not
properly lubricated, and m ounted, they will
stretch thin in the tire bead and rim region. This
will cause premature wear.
1. Clean the inside of the casing.
2. Insert the tube in the tire and inflate until it is nearly
rounded out.
3. Inspect the rim for rust scale and bent flanges.
Clean rust scale and straighten the flanges
where necessary.

4. Apply a solution of neutral vegetable oil soap to the
inside and outside of the tire beads, and also the rim
side of the tube.
Use a brush or a cloth swab.
Do not allow the soap solution to run down into
the tire.
5. Follow the standard procedure when mounting the
tube and tire on a drop center rim. Be sure the tire is
centered on the rim so the beads are out of the rim well
before inflating. Do not allow the tire to hang loosely on
the wheel while inflating.
6. Center the valve and pull it firmly against the rim. Hold
in this position and inflate until the tire beads are firmly
seated on the rim against the flanges.
7. Remove the valve core to completely deflate the tire.
8. Reinflate the tire to the recommended pressure.
R efer to Tire Load Lim its And In fla tio n
Pressure at the end of this section.
Tubeless Tires
| j | Im portant
Only use rims approved for radial tire usage by the
rim manufacturer.
1. Clean the rim.
Remove all rust and other foreign material.
2. Lubricate tire beads and rim bead seats with an
approved rubber lubricant.
N O T IC E :
Do
not
u se
s ilic o n e
base
lubricants this could cause the tire to slip on
the wheel.
3. Inflate the tire to operating pressure.
Due to the construction of radial truck tires,
particularly in the lower sidewall and bead area,
it may be difficult to get the tire to take air.
An inflation aid may be necessary to help seat
the bead of tubeless radial tires. Two types of
inflation aids are commercially availablemetal
rings which use compressed air to seat beads,
and rubber rings which seal between the tire
bead and rim bead seat allowing the bead to
move out and seat. Lubrication is necessary with
both aids.
4. Check the spacing between the rim flange and one of
the three lower sidewall rim line rings while the tire is
laying flat to verify bead seating.
Measurements must be taken each 90 degrees
around the circumference of the rim flange.
If the spacing is uneven around the bead from
side to side, repeat steps 1 through 3, then
recheck.
Im portant
This procedure must be followed to insure proper
bead seating in order to prevent bead deformation.
Radial tires, as well as bias tires, must be mounted
and inflated in accordance with safety precautions
noted in RMA Radial and Bias Truck Tire Service
Manuals.
INSTALLING THE TIRE AND

WHEEL ASSEMBLY
CAUTION: Before re-installing the wheels,
remove any build up of corrosion on the wheel
m ounting surface and brake drum or disc
m o u n tin g s u rfa c e by s c ra p in g and w ire
b ru s h in g . In s ta llin g w h e e ls w ith goo d
m e ta l-to -m e ta l c o n ta c t at th e m o u n tin g
surfaces can cause wheel nuts to loosen. This
can lead to a wheel coming off while the vehicle
is moving, possibly causing loss of control.
SINGLE WHEELS
1. Wheel and tire assembly in position on the hub/rotor,
and lug nuts installed loosely.
2. Turn the wheel until one nut is at the top of the bolt
circle. Tighten the nut just snug.
3. Snug up the remaining nuts criss-cross to minimize
runout.
Tighten
Nuts to Specifications at the end of this section.
Tighten evenly and alternately to avoid excessive
runout (figure 7).
DUAL WHEELS
1. Inner and outer wheel and clam p ring on the rear
wheel, or wheel and clam p ring on the front wheel.
Be sure the pins on the clam p ring face outward.
2. Lub nuts finger tight.
Tighten
Nuts to Specifications at the end of this
section.
For P 3 0 models, tighten to 210 N m (155 ft.
lbs.), then tighten again to 237 N m (175 ft.
lbs.).
T ig h te n e v e n ly and a lte rn a te ly to avoid
excessive runout (figure 7).

Clean the surface of any contaminants using
Prekleno.
Apply #801 Metal Conditioner, taking care to use
rubber gloves and a clean cloth during the
application. Keep the surface wet while applying.
Im portant
Make sure #801 Metal C onditioner is reduced one
part metal conditioner to three parts of water.
Wipe off #801 Metal C onditioner carefully w hile the
surface is still wet. Use a clean, dry cloth.
4. Apply the clear coat.
Apply R & Ms 893 2K Clear with 894 Urethane
Catalyst Hardener. Refer to the label for specific
directions.
Wear proper respiratory protection such as a 3M
Paint Respirator (part number 06984) or Easi-Air
Respirator (part number 06986) or equivalent.
5. Allow the wheel to air dry overnight (minimum)
before installing on the vehicle.
6. Attach balance weights and install the wheel and
tire assembly on the vehicle.
Mount the weights in the marked positions and
remove the masking from the tire.
WHEEL AND TIRE BALANCING

Figure 8- -Underbody Swing Out Spare Tire
Carrier (RPO P10)
Measure
Lateral runout should not exceed 3.18 mm (0.125
inches) on the front wheel or 4.76 mm (0.187 inches)
on the rear wheel.
ALUMINUM WHEEL REFINISHING

Remove the tire and wheel assembly from the vehicle.
Mark the position of the wheel weights on the tire for
correct reinstallatio n after recoating the wheel.
Remove the wheel weights and mask off the tire.
1. Remove the original clear coating.
Apply a chemical stripper such as 3M brand
Troubleshooter to the wheel rim surface.
Wait 10 to 15 minutes, then wet scrub the surface
using a 3M #98 Scotchbrite Cleaning Pad (3M
part number 07445).
Rinse the surface thoroughly with clean water.
CAUTION: Use of eye goggles is necessary to

prevent personal injury.
2. Remove surface oxidation.
Use 3M Superbuff Buffing Pad (3M part number
05701) and a medium type compound such as
3M part number 05955 or 05931.
Hose off the rim with water and scrub with a
small brush to remove excess compound, then
air blow dry.
3. Recoat the wheels.
To insure successful, accurate balancing, the following

precautions must be observed:
The wheel and tire must be clean and free of all
foreign matter.
The tire should be in good condition and properly
mounted using the balance mark on the tire, if
any, or lined up with the inflation valve.
Bent wheels that have a runout over 1.6 mm
(Ve-inch) should be replaced.
Inspect the wheel and tire assembly to determine
if an out-of-round condition exists.
Im portant
A s e v e re o u t-o f-ro u n d c o n d itio n c a n n o t be
balanced o ut. A wheel and tire assembly having
an o u t-o f-ro u n d c o n d itio n e xce e d in g 4.7 mm
(3/i6-inch) is not suitable for the front of the vehicle.
Its use on the rear of the vehicle must be governed
by its general condition and whether the roundness
problem seriously detracts from overall ride quality.
Follow the wheel balancer m achine instructions
while performing the balancing operation.
OPTIONAL SPARE TIRE CARRIERS

UNDERBODY SWING OUT SPARE TIRE CARRIER
(RPO P10)
The underbody swing out spare tire carrier is standard
equipm ent on RV 10/1500 series pickups. It is available as
an option (RPO P10) on RV 20/2500 and 30/3500 series
pickups (figure 8).
Figure 9Underbody Glide Out Spare Tire Carrier (RPO P11)

UNDERBODY GLIDE OUT SPARE TIRE CARRIER
(RPO P11)
SIDE PANEL MOUNTED SPARE TIRE CARRIER

(RPO P13)
The underbody glide out spare tire carrier is available

as an option (RPO P11) on all RV series pickups (figure
The side panel mounted spare tire carrier is available

as an option on all C-K series pickups (figure 10).
9).
SPECIFICATIONS
WHEEL RUNOUT
Steel Wheels
Aluminum Wheels
Radial Runout
1.01 mm (0.04 inches)
0.76 mm (0.03 inches)
Lateral Runout
1.14 mm (0.045 inches)
0.76 mm (0.03 inches)
WHEEL STUD NUT TORQUE (SINGLE FRONT AND REAR WHEELS)

Series
Number Of Studs
Nut Torque
studs
studs
studs
studs
studs
studs
140 N m (100 ft. lbs.) (steel wheels)

140 N m (100 ft. lbs.) (aluminum wheels)
160 N-m (120 ft. lbs.) (all)
160 N m (120 ft. lbs.) (all)
G 10/1500-20/2500
G 10/1500-20/2500
G30/3500
5 studs
5 studs
8 studs

160 N m (120 ft. lbs.) (all)
P20/2500 & 30/3500
8 studs
160 N m (120 ft. lbs.) (all)
R 10/1500
V10/1500
R10/1500
V10/1500
RV20/2500
RV30/3500
5
6
5
6
8
8
WHEEL STUD NUT TORQUE (SINGLE FRONT AND DUAL REAR WHEELS)
Series
Number Of Studs
Nut Torque
RV30/3500
8 studs
190 N m (140 ft. lbs.) (all)
G 30/3500
8 studs
190 N m (140 ft. lbs.) (all)
P 30/3500
P 30/3500
8 studs
10 studs
190 N-m (140 ft. lbs.) (with RPO JB8)

210 N-m (155 ft. lbs.) (with RPO JF9)

TIRE AND WHEEL LOAD LIMIT CHARTS
(TIRE * WHEEL LOAD LIMITS ARE SHOWN BELOW. VEHICLE LOADING MUST BE LIMITED
SUCH THAT NEITHER THE WHEEL OR TIRE INFLATION PRESSURE OR LOAD LIMITS ARE
EXCEEDED).
RADIAL TIRE SIZE AND LOAD LIMITS - kg (LBS)
Metric Radial Tires Used As Singles
Metric Radial Tires Used As Singles (Cont.)

Inflation Pressure - kPa (PSI)
400 (58)
Tire
Load
Size
Range
2 5 0 (3 6 )
LT215/85R16
695
(1532)
790
(1742)
(1940)
LT215/85R16
695
(1532)
790
(1742)
880
(1940)
LT235/85R16
790
(1742)
900
(1984)
1000
(2205)
LT235/85R16
790
(1742)
900
(1984)
1000
(2205)
450 (65)
500 (73)
550 (80)
1290
(2844)
1380
(3042)

|
3 0 0 (4 4 )
3 5 0 (5 1 )
880
965
(2127)
1050
(2315)
1100
(2425)
1190
(2623)
1100
(2425)
1190
(2623)
Metric Radial Tires Used As Duals (Cont.)

400 (58)
450 (65)
870
(1918)
955
(2105)
500 (73)
550 (80)
Metric Radial Tires Used As Duals

Tire
Load
Size
Range
250 (36)
LT215/85R16
630
LT215/85R16

|
300 (44)
350 (51)
(1389)
720
(1587)
800
(1764)
630
(1389)
720
(1587)
800
(1764)
Bias Tires Used As Singles (Cont.)

BIAS TIRE SIZE AND LOAD LIMITS -
kg (LBS)
345 (50)
379 (55)
993
(2190)
1048
(2310)
1107
(2440)
993
(2190)
1048
(2310)
1107
(2440)
414 (60)
448 (65)
483 (70)
517 (75)
1211
(2670)
1261
(2780)
Bias Tires Used As Singles

Tire
Load
Size
Range
207 (30)
7 50 16
735
(1620)
803
(1770)
875
(1930)
7 50-16
735
(1620)
803
(1770)
875
(1930)
(2060)
7 50-16
735
(1620)
803
875
(1930)
934
2060

|
241 (35)
(1770)
276 (40)
310 (45)
934
(2060)
934
1161
(2560)
Bias Tires Used As Duals (Cont.)

Inflation Pressure kPa (PSI)
345 (50)
379 (55)
414 (60)
448 (65)
483 (70)
5 17 ^75 ^
Bias Tires Used As Duals

Tire
Load
Size
Range
207 (30)
7 50-16
649
(1430)
710
767
823
(1565)
(1690)
(1815)
7 50-16
649
(1430)
710
(1565)
767
(1690)
823
(1815)

|
241 (35)
276 (40)
310 (45)
B-07548
875
(1930)
925
(2040)
971
(2140)
______________________________________________ B-07549
Figure 11Tire Load Limits and Inflation

Pressure (RV)

Pressure (RV)
TIRE LOAD LIMITS AND

INFLATION PRESSURE
WHEEL CODES AND LOAD LIMITS
Refer to Figures 11, 12, 14, 15, 17, and 18 for tire load
limits given an inflation pressure range.
Refer to Figures 13, 16, and 19 for wheel load limits for
each wheel size (coded).
Code *
AA
Wheel
Size
Max. Load
kg (lbs.)
16 x 6.5
Tire Load Limits: Bias Tire Used As Singles kg (lbs.) (Cont.)
Max. Pressure
kPa (psi)
1,381 (3 045)
621 (90)
AF
16x6
1,107 (2 440)
517 (75)
BF
16 x 16.5
1,261 (2 780)
586 (85)
BK
15x7
757 (1 670)
276 (40)
CF
15x7
757 (1 670)
276 (40)
CK
15x8
866 (1 910)
276 (40)
DAB
15x8
921 (2 030)
276 (40)
414
(60)
379
(55)
448
(65)
8 82
928
(1 9 45 )
(2 0 4 5 )
1016
1 066
(2 240 )
(2 3 50 )
552
(80)
517
(75)
483
(70)
1016
1066
1120
1166
1216
(2 240 )
(2 3 5 0 )
(2 4 7 0 )
(2 5 70 )
(2 6 80 )
DAC
15x8
921 (2 030)
282 (41)
GBA
15x8
900 (1 984)
282 (41)
GBB
15 x 7
921 (2 030)
282 (41)
UA
15x7
921 (2 030)
282 (41)
XAH
15 x 6
900 (1 984)
438 (70)
XH
15x6
719 (1 585)
276 (40)
7 76
816
CC
1 5x,6
757 (1 670)
379 (55)
(1 710)
(1 8 00 )
XX
15x6
925 (2 040)
483 (70)
Tire Load Limits: Bias Tires Used As Duals kg (lbs.) (Cont.)

448
(65)
414
(60)
379
(55)
552
(80)
517
(75)
483
(70)
Tire Load Limits: Radial Tires Used As Singles kg (lbs.) (Cont.)
* W heel code is located on the wheel ju s t to the rig h t o f the valve stem
hole.
Inflation Pressure kPaJPSI)
379
(55)
448
(65)
414
(60)
552
(80)
517
(75)
483
(70)
9 57
1016
1066
1120
1166
1216
(2 110)
(2 240 )
(2 3 50 )
(2 4 70 )
(2 570 )
(2 6 8 0 )
B-08072
B-08075

Pressure (G)
Figure 13Wheel Codes and Load Limits (RV)

TIRE AND WHEEL LOAD UMIT CHARTS
(Tire and wheel load limits are shown below. Vehicle loading must be limited so that neither
Wheel Code and Load Limits
the wheel or tire inflation pressure or load limits are exceeded)
Tire Load Limits: Bias T im Used As Singles kg (lbs)

Tire
Size
8.0016.5
8.0016.5
8.7516.5
8 .7 5 16.5
Load
Range
C
207
(30)
345
(50)
310
(45)
276
(40)
241
(35)
Code *
617
676
730
785
(1 3 60 )
(1 4 90 )
(1 610)
(1 730 )
617
676
730
7 85
835
(1 3 60 )
(1 4 9 0 )
(1 610)
(1 730)
(1 8 4 0 )
712
7 80
839
903
957
(1 5 70 )
(1 720 )
(1 8 5 0 )
(1 990 )
(2 110)
712
780
839
903
957
(1 5 70 )
(1 720 )
(1 8 5 0 )
(1 990 )
(2 110)
8 00165
8 0016.5
Load
Range
C
207
(30)
542
594
(1 195)
(1 310)
689
642
.
il
345
(50)
310
(45)
276
(40)
241
(35)
...
(1 520)
542
594
642
689
735
(1 195
(1 310)
(1 415)
(1 520)
(1 620)
Tire Load Limits: Radial Tires Used As Singles kg (lbs)

Tire
Size
8 .7 5
R 1 6.5
Load
Range
E
207
(30)
241
(35)
276
(40)
Max. Load
- kg (lbs.)
Max. Pressure
- kPa (PSI)
DAS
15 x 6.5
835 (1 843)
282 (41)
GBC
15 x 6.5
835 (1 843)
282 (41)
XH
15 x 6
719 (1 585)
XAH
15 x 6
900 (1 984)
483 (70)
VH
16 5 x 6
1216 (2 680)
586 (85)
XJ
16.5 x 6.75
1216 (2 680)
586 (85)
276 (40)
'W heel code is located on the wheel just to the right of the valve stem hole.
B-08076
1 ire Load Limits: Bias Tires Used As Duals kg (lbs)
Tire
Size
Wheel
Size
345
(50)
310
(45)
712
780
839
903
(1 5 70 )
(1 7 20 )
(1 8 50 )
(1 9 9 0 )
B-08074

Pressure (G)
Figure 16Wheel Codes and Load Limits (G)
TIRE LOAD LIMIT CHARTS
TIRE LOAD LIMIT CHARTS (CONT.)
(Tire load limits at different inflation pressures are shown below. Vehicle loading must be
limited such that neither the tire inflation pressures or load limits are exceeded)
METRIC RADIAL TIRES Tire
Size
Load
Range
LT215/85R16
LT215/85R16
METRIC RADIAL TIRES (CONT.) -
Single
Dual
250 (36)
300 (44)
350 (51)
695 (1532)
790 (1742)
880 (1940)
630 (1389)
720 (1587)
800 (1764)
695 (1532)
790 (1742)
880 (1940)
630 (1389)
720 (1587)
800 (1764)
790 (1742)
900 (1984)
790 (1742)
900 (1984)
LT235/85R16
kg (LBS.)
kg (LBS.)

400 (58)
450 (65)
965 (2127)
1050(2315)
870 (1918)
955 (2105)
1000 (2205)
1100 (2425)
1190 (2623)
1000 (2205)
1100 (2425)
1190 (2623)
500 (73)
550 (80)
1290 (2844)
1380 (3042)
LT235/85R16
STANDARD RADIAL TIRES Tire
Load
Size
Range
Single
Dual
8R19.5
kg (LBS.)
STANDARD RADIAL TIRES (CONT.) -

310 (45)
345 (50)

379 (55)
414 (60)
448 (65)
483 (70)
517 (75)
552 (80)
1030 (2270)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
1012 (2230)
1066 (2350)
1116 (2460)
BIAS TIRES -
kg (LBS.)
BIAS TIRES (CONT.) -
Load
Single
Range
Dual
207 (30)
241 (35)
276 (40)
310 (45)
7.50-16
735 (1630)
803 (1770)
875 (1930)
934 (2060)
823 (1815)
7.50-16
7.50-16
kg (LBS.)
Tire
Size
kg (LBS.)
345 (50)
379 (55)
414 (60)
1107 (2440)
448 (65)
483 (70)
517 (75)
649 (1430)
710 (1565)
767 (1690)
735 (1620)
803 (1770)
875 (1930)
934 (2060)
993 (2190)
1048 (2310)
649 (1430)
710 (1565)
767 (1690)
823 (1815)
875 (1930)
925 (2040)
971 (2140)
735 (1620)
803 (1770)
875 (1930)
934 (2060)
993 (2190)
1048 (2310)
1107 (2440)
1161 (2560)
1211 (2670)
1261 (2780)
957 (2110)
1030 (2270)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
839 (1850)
903 (1990)
957 (2110)
1012 (2230)
1066 (2350)
1116 (2460)
957 (2110)
1030 (2270)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
839 (1850)
903 (1990)
957 (2110)
1012 (2230)
1066 (2350)
1116 (2460)
1166 (2570)
1216 (2680)
8-19 5
S
D
8-19.5
S
D
B-08077

Pressure (P)
B-08078

Pressure (P)
WHEEL CODE AND LIMITS
Code*
Wheel
Size
Max Load
kg (Lbs.)
Max Pressure
kPa (PSI)
AA
16 x 6.5 L
1381 (3045)
621 (90)
AF
16 x 6 K
1107 (2440)
517 (75)
BF
16 x 6.5 L
1261 (2780)
586 (85)
ZT
19.5 x 6
1261 (2780)
655 (95)
ZY
19.5 x 6
1152 (2540)
552 (80)
Wheel code is located on the wheel just to the right of the

valve stem hole.
B-08079
Figure 19Wheel Codes and Load Limits (P)
PROPELLER SHAFT 4A-1
SECTION 4A
\
PRO PELLER SHAFT

manual as indicated at appropriate locations by the term inology Notice: See NOTICE on page 4A-1 of this section .
NOTICE: All propeller shaft to pinion flange fasteners are important attaching parts in that they could affect the
performance o f vital parts and systems, and/or could result in major repair expense. They must be replaced with
one o f the same part number or with an equivalent part if replacem ent becomes necessary. Do not use a replace
m ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to
assure proper retention of all parts.
CONTENTS
SUBJECT
PAGE
Description..................................................................................................................................................................... 4A- 1
Propeller S h a ft...........................................................................................................................................................4A- 1
Center B earing...........................................................................................................................................................4A- 1
Universal J o in t...........................................................................................................................................................4A- 1
Diagnosis Of Driveline Vibration (Road Test)........................................................................................................... 4A- 3
Diagnosis Of Propeller Shaft and Universal J o in t................................................................................................... 4A- 4
On-Vehicle S e rv ic e ...................................................................................................................................................... 4A- 5
Propeller Shaft Balance Check................................................................................................................................4A- 5
Propeller Shaft Runout C h e c k ................................................................................................................................4A- 5
Propeller Shaft Replacement (Rear Drive)............................................................................................................. 4A- 6
Propeller Shaft Replacement (Front D rive)............................................................................................................4A- 7
Lubrication.....................................................................................................................................................................4A- 9
S p e cifica tio n s...............................................................................................................................................................4 A - 10
Special T o o ls .................................................................................................................................................................4A-10
DESCRIPTION
PROPELLER SHAFT
Torque is transmitted from the transm ission to the rear
axle through one or more propeller shafts and universal
joint assemblies. The num ber of propeller shafts and
universal joint assemblies vary with the vehicle wheel
base, and the combination of transm ission, transfer case
(front drive) and rear axle equipment.
All propeller shafts are the balanced tubular type (figure
1). A splined slip joint is provided in some drivelines and
others use a companion flange at the transmission end of
the driveline. If two or more propeller shafts are used on a
vehicle the slip joint is usually at the forward end of the
rear propeller shaft.
Phasing
The propeller shaft is designed and built with the yoke
lugs (ears) in line with each other (figure 1). This design
produces the smoothest running shaft possible, and is
called phasing.
Vibration can be caused by an out of phase propeller
shaft. The propeller shaft will absorb vibrations from
speeding up and slowing down each tim e the universal
joint goes around. This vibration would be the same as a
person sn ap ping a rope and w atch in g the w ave
reaction flow to the end. A propeller shaft working in
phase would be sim ilar to two persons snapping a rope at

the same time, and watching the waves meet and
cancel each other out. In comparison this would be the
same as the universal joints on a propeller shaft. A total
cancellation of vibration produces a smooth flow of power
in the driveline. It is very important to reference mark the
p ro p e lle r s h a ft b efo re rem oval, to a ssure pha sed
in s ta lla tio n a lig n m e n t. Som e p ro p e lle r shafts have
alignm ent marks or arrows stamped on the shaft at the
tim e of production.
CENTER BEARING
Center bearings support the driveline when two or more
propeller shafts are used. The center bearing is a ball
type bearing mounted in a rubber cushion that is attached
to a frame crossmember. The bearing is pre-lubricated
and sealed by the m anufacturer (figure 2).
UNIVERSAL JOINT
A universal joint is two Y-shaped yokes connected by a
crossm em ber called a spider. The spider is shaped like a
cross having arms of equal length called trunnions (figure
3).
4A -2 PROPELLER SHAFT
Universal joints are designed to handle the effects of

v a rio u s lo a d in g s a n d re a r a x le w in d u p d u rin g
acceleration. W ithin the designed angle variations the
universal joint will operate efficiently and safely. When the
design angle is changed or exceeded the operational life
of the joint may decrease.
The trunnion bearings used in universal joints are the
needle roller type. The needle rollers are held in place on
the trunnions by round bearing cups. The bearing cups
are held in the yokes by e ithe r (depending on the

manufacturer) snap rings or injected plastic.
When a driveline has a large or deep angle a constant
velocity joint is used. Essentially, the constant velocity
joint is made of two universal joints coupled by a yoke and
phased for constant velocity. A centering ball socket
between the joints keeps a relative position between the
two joints. This centering device causes each of the two
units to operate through one half of the complete angle
between the propeller shaft and the differential carrier
6. R e ta in e r
7. P in io n F la n g e
8. Yoke and C ro s s
A s s e m b ly
S p lin e d S h a ft
C ap
W a sh e r
Seal (Cork)
N ut
T ra n s m is s io n Yoke
W asher
B o lt
U nive rsa l J o in t
1.
2.
3.
4.
5.
H a n g e r A s s e m b ly and C ro s s m e m b e r
C enter Bearing S u pp o rt
F ro n t P ro p e lle r S h a ft
Rear P ro p e lle r S h a ft
B o lt
S lip Yoke
B-06720
Figure 2Center Bearing and Propeller Shaft Detail
A. Ball S o c k e t
Figure 3Simple Universal Joint
B-06813
Figure 4Constant Velocity Joint
(figure 4). The ball socket on a constant velocity universal

join t requires periodic lubrication through the fitting
provided.
DIAGNOSIS OF DRIVELINE VIBRATION

(ROAD TEST)
Four major component groups are usually the cause of
or are related to vibration. When a technician is road test
ing a vehicle for vibration he must remember the four ma
jor component groups:
1. Engine and mounts.
2. Clutch and transmission.
3. Tires, wheels and brake drums.
4. Propeller shaft and universal joints.
Before road testing a vehicle, check the following:
1. In or out of phase propeller shaft.
2. All fasteners for tightness at universal joints, wheel
lugs and engine mounts.
3. T ire a ir pressure.
4. Load conditions.
ROAD TEST
A technician should road test the vehicle to diagnose
exactly what the com plaint is. Record the speed and rpm
at which the greatest vibration occurs. The vibration is
likely to be in two places, in the steering wheel or in the
seat bottom. The road test can be helpful in locating the
vibration source either forward or aft.
COAST TEST
Drive the vehicle past the vibration speed, shift into
neutral and coast back through the vibration speed. In
this test two kinds of vibration normally occur; a shaking
or a buzzing. A shaking vibration is usually tires or a
wheel and brake drum /disc assembly problem. A buzzing
vibration is usually a driveline problem.
4A-4 PROPELLER SHAFT
DIAGNOSIS OF THE PROPELLER SHAFT AND

UNIVERSAL JOINT
PROBLEM
Leak At The Front
Slip Yoke (An
Occasional Drop Of
Lubricant Leaking
From The Splined
Yoke Is Normal And
Requires No
Attention)
POSSIBLE CAUSE
CORRECTION
1. Rough surface on splined yoke; burred,

nicked or worn.
1. Replace the seal. Minor burrs can be

sm oothed by careful use of crocus
cloth or fine stone honing. Replace the
yoke if badly burred.
2. Replace the transm ission rear oil seal
and replenish the transm ission oil.
2. Defective transm ission rear oil seal.
Universal Joint Noise
1.
2.
3.
4.
Ping, Snap, Or Click

In Drive Line (Usually
Heard On Initial Load
After The
Transmission Is In
Gear; Forward Or
Reverse)
1. Loose bushing bolts on the rear springs

or upper and lower control arms.
2. Loose or out of phase companion flange.
Knocking Or Clunking
Noise In The Driveline
When Operating The
Vehicle In A Floating
Condition In High Or
Neutral Gear At 10
MPH (16 km/h)
1. Worn or damaged universal joint.
Roughness Or
Vibration
Center bearing.
Worn universal joint bearings.
Improper lubrication.
Loose flange bolts.
2. Side gear hub counterbore in the dif

ferential is worn oversize.
1. Bent or dented propeller shaft.

2. Undercoating on propeller shaft.
3. Tire unbalance, 30-80 mph (48-129 km/
h). Not throttle conscious.
4. Tight universal joints.
5. Worn universal joints.

6. Burrs or gouges on companion flange.
Check snap ring locating surfaces on
flange yoke.
7. Propeller shaft, parking brake drum or
companion flange is unbalanced.
8. Incorrect rear joint angle. The angle is
usually too large when it is a factor.
9. Excessive looseness at the slip spline.
10. Distorted or damaged yokes or flanges.
11. Yokes out of phase.
12. Propeller shaft runout at 50 mph (80 km/

h). Throttle conscious.
1.
2.
3.
4.
Replace the center bearing.

Replace.
Lubricate as directed.
Tighten to Specifications later in this
section.
1. Tighten the bolts to specified torque.

2. Remove companion flange, turn 180
degrees from its original position, lubri
cate the splines and install. Tighten the
bolts and pinion nut to specified torque.
1. Replace the worn or damaged univer

sal joint.
2. Replace the differential case and/or the
sidegears.
1. Replace propeller shaft.

2. Clean propeller shaft.
3. Balance or replace as required.
4. Impact yokes with a shaft hammer to
free up. If unable to free up or if joint
feels rough when rotated, replace.
5. Replace.
6. R ew ork or re p la c e th e co m p a n io n
flange.
7. Check for a missing balance weight on
the propeller shaft. Rotate the com pan
ion flange 180 degrees.
8. Check and correct trim height at curb
weight. Check and correct joint angle.
9. Replace necessary parts.
10. Install new yokes or flanges.
11. Remove companion flange, turn 180
degrees from the original position, lu
bricate the splines and install. Tighten
bolts to specified torque.
12. Check propeller shaft runout at front
and rear. Should be less than specified.
If above, rotate propeller shaft 180 de
grees and recheck. Replace the propel
le r s h a ft if r u n o u t is s till o v e r
specification.
DIAGNOSIS OF THE PROPELLER SHAFT AND

UNIVERSAL JOINT (CONTINUED)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Scraping Noise
Slinger, companion flange, or end yoke

rubbing on rear axle or center bearing.
Correct the interference.
Roughness Above 35
MPH (56 km/h) Felt
And/Or Heard
Tires unbalanced or worn.
Balance or replace as required.
Squeak
1. Lack of lubricant.
1. Lubricate joints and splines. Also check

for worn or brinelled parts.
2. Replace or lubricate.
2. Center bearing.
Whine Or Whistle
Shudder On
Acceleration, (Low
Speed)
Center support bearing.
Place the vehicle on a hoist with rear

wheels free to rotate and diagnose for
source of noise, replace.
1. Loose or m issing bolts at the center

bearing or flanges.
2. Incorrectly set front joint angle.
3. Worn universal joint.
1. Replace or tighten bolts to specified

torque.
2. Shim under the transmission support
mount to change the front joint angle.
3. Replace.
ON-VEHICLE SERVICE
PROPELLER SHAFT
BALANCE CHECK
Raise the vehicle on a twin post hoist so the wheels
can spin.
1. Tire and wheel assemblies and the brake drums.

DO NOT APPLY THE BRAKE W ITH THE
DRUMS REMOVED.
L*
Inspect
Propeller shaft, universal joints and attachments
for mud, undercoating or loose fasteners.
igi
Clean
Propeller shaft, universal joints and attachments.
U Tighten
Any loose attachments or fasteners.
Important
Run the vehicle in gear at the speed where the
disturbance peaks; observe the intensity of the
disturbance.
Stop the engine.
2. Propeller shaft.
Rotate the propeller shaft 180 degrees from the

original position.
Install or Connect
1. Propeller shaft.
Determine the position which gives the best
balance.
2. Rear drums, wheel and tire assemblies.
Determine the position which gives the best
driveline response by road testing the vehicle for
a final check of the propeller shaft balance.
Unacceptable balance, replace the propeller
shaft.
PROPELLER SHAFT
RUNOUT CHECK
Noise or vibration at high speed could be caused by a
bent propeller shaft. The propeller shaft could have been
damaged by rough handling or a collision. Check for
propeller shaft straightness.
1. Raise the vehicle on a twin post hoist so the wheels
can spin.
2. Attach a dial indicator having a magnetic base to a
smooth place on the vehicle underbody.
3. Take dial indicator readings at the propeller shaft
c h e c k p o in ts show n in fig u re 5. For ru n o u t
specifications, refer to figure 6.
F ro n t R u n o u t
C e n te r R u n o u t
Rear R u n o u t
S p lin e d S h a ft R u n o u t at
Tapered H o le in S p lin e d End
O ne Piece P ro p e lle r S h a ft
B-07678
Figure 5Checking Propeller Shaft Runout

Im portant
Do not attach the dial indicator base at a weld.
4. With the transmission in neutral, hand rotate the axle
pinion flange or the transmission yoke and take the
necessary dial indicator readings on the propeller
shaft. Record the readings. Models having a two-piece
driveline, measure the rear propeller shaft runout
(figure 5). Reference mark the position of the rear
propeller shaft yoke to the pinion flange, then remove
the rear propeller shaft and measure the front propeller
PR O PELLER
SHAFT
FR O N T
CHECK
CEN TER
CHECK
REAR
CHECK
O N E PIECE
.040
.050
.055
TW O PIECE
FR O N T
.020
TW O PIECE
REAR
.030*
.008A
.030
shaft runout on the tube and at the tapered hole on the

splined shaft end (figure 5). If the runout exceeds
specification, rotate the propeller shaft 180 degrees at
the companion flange and install. Check the runout.
5. If the runout is still over specification at one or more
check points, replace the propeller shaft after checking
for vibration or noise. Check the runout on the
replacement propeller shaft.
6. If the new propeller shaft runout is over specification,
check for a bent companion flange.
Im portant
The splined end of the front propeller shaft is
critical to the smooth operation of a two-piece
driveline. Be sure the dial indicator readings are
accurate.
PROPELLER SHAFT
REPLACEMENT (REAR DRIVE)
.035
1.
A N O T E : T h is m e a s u re m e n t m u s t be ta ken at
th e ta p e re d h o le on th e s p lin e d s h a ft a fte r th e
rear p ro p e lle r s h a ft is rem oved.
2.
3.
Tool Required:
J-33051, Driveshaft Wrench.
Skid plate if used.
Reference mark the propeller shaft (4) to pinion
flange (7) connection.
Bolts (5).
Retainers(6).
Im portant
* NOTE: T h is m e a s u re m e n t m u s t be ta ken
w ith th e rear p ro p e lle r s h a ft m o u n te d on th e
fro n t s h a ft w h ic h is w ith in s p e c ific a tio n s .
B-07557
Figure 6Propeller Shaft Runout Specifications
Do not pound on the original propeller shaft yoke

ears. The injection joints may fracture. Never pry
or place any tool between a yoke and a universal
joint.
4. Yoke and cross assembly (8).
Tape bearing cups to prevent the loss of bearing
rollers.
5. Propeller shaft (4).
Slide the propeller shaft (4) forward.

Lower the propeller shaft (4) and withdraw under
the rear axle.
Do not allow the universal joint (17) to incline
greatly; the joint may fracture.
Tighten
Nut (13) to torque specification later in this

section. Maintain alignment (figure 7).
Models with a two-piece propeller shaft

6. Nut (13).
7. Bolt (16) and washer (15).
8. Center bearing support (2).
Support the propeller shaft (3).
9. Cap (10).
10. Washer (11).
11. Seal (12).
12. Front propeller shaft (3).
Always support the propeller shaft (3).
Do not allow the universal joint (14) to bend
deeply as the universal joint could fracture.
Withdraw the propeller shaft (3) with a rearward
movement.
Im portant
6.
7.
8.
9.
10.
Clean
All parts.
Inspect
1. Outer diameter of transmission yoke (14) for burrs. Any
burring will damage the transmission seal.
2. For proper installation and uniform seating of bearing
cups.
3. Slip yoke (18) splines for wear.
4. For twisted slip yoke splines or possibly the wrong
universal joint.
|~n-| Install or Connect (Figures 2 and 7)

One-Piece Propeller Shaft
1. Propeller shaft (4) into the transmission.
Lubricate slip joint.
2. Yoke and cross assembly (8) onto the pinion flange (7).
Align the reference marks on the pinion flange
(7) and the propeller shaft rear yoke (8). Seat the
yoke properly.
3. Retainer (6).
NOTICE: See N otice on page 4A-1 of this
section.
4. Bolt (5).
Tighten
Bolt (5) to torque in Specifications at the end
of this section.
Two-Piece Propeller Shaft

1. Propeller shaft (3) into the transmission.
Be sure joint is lubricated.
Bottom the propeller shaft (3) yoke in the
transmission.
2. Center bearing support (2) onto hanger (1).
Align the center bearing support 90 degrees to
the propeller shaft (3, 4) center lines. Refer to
figure 7.
3. Bolt (16).
4. Washer (15).
5. Nut (13).
11.
Set the transmission yoke (14) ears in a vertical

position for proper phasing (figure 7).
Cap (10).
Washer (11).
Seal (12).
Locate the bridged tooth on the splined shaft (9).
Slip yoke (18) onto the splined shaft (9).
Mate the missing tooth in the yoke (18) with the
bridged tooth on the splined shaft (9) figure 7.
Be sure the slip yoke (18) ears are horizontal,
figure 7.
Propeller shaft (4).
Align reference marks.
Check bearings for proper fit.
Retainer (6).
NOTICE: See N o tic e on page 4A-1 of this

section.
12. Bolt (5).
Check for proper joint fit.
Tighten
B o lts (5) to s p e c ifie d to rq u e . R e fe r to

Lubricate the slip yoke (18).
PROPELLER SHAFT
REPLACEMENT (FRONT DRIVE)
Tool Required:
J-22610, Keystone Clamp Pliers.
Remove skid plate if used.
Reference mark the relationship of the propeller
shaft (14) to the front axle and the transfer case
flange (17).
1. Slip yoke (13) from the front axle yoke (12).
Nut (10), washer (11) and U-bolt (15).
Bolt (20) and retainer (22).
Im portant
Do not pound on the joint to disconnect.
2. Bolt (18) at the flange (17).
3. Boot (21) if used.
Release boot retainers using J-22610.
Slide the propeller shaft (14) forward, enough to
disengage, then withdraw the propeller shaft (14)
rearward.
Avoid dropping cap assemblies from the yoke
ends.
ijj| Clean
All parts.
H a n g e r A s s e m b ly
C e n te r B e aring S u p p o rt
T ra n s m is s io n Yoke
S lip Yoke
H o riz o n ta l C e n te r Lin e A t T he Yoke
90 1 D egree A n g le F or S lo tte d H a n g e r H o le s
V e rtic a l C e n te r L in e A t T he Yoke
B-07562
Figure 7Alignment for Two-Piece Propeller Sahft In Phase, G and V Models
'
12
I*
'
11. W a sh e r
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Figure 8Front Propeller Shaft and Driveline Detail
F ro n t A x le Yoke
S lip Yoke
P ro p e lle r S h a ft A s s e m b ly
U -b olt
T ra n sfe r C ase
F lan ge
B o lt
C o n s ta n t V e lo c ity J o in t
B o lt
Boot
R e ta in e r
F ro n t A x le A s s e m b ly
C la m p
B-07561
IP
Inspect
Splines for damage, wear, burrs and twisting.

Bearings for wear.
Propeller shaft (14) for straightness.
Mate the joint using reference marks.

U-bolt, washer (11) and nut (10).
Retainer (22) and bolt (20).
NOTICE: See N o tic e on page 4A-1 of this
section.

Tools Required:
J-22610, Keystone Clamp Pliers.
J-25512, CV Propshaft Lube Gun (Vs-inch pipe).
J-25512-2, Needle point.
Lubricate the slip yoke (13) before installing the
boot (21). Refer to Lubrication later in this
section.
1. Boot (21) if used.
Retainers (24) using J-22610.
2. Slip yoke (13) to the axle yoke (12).
Adjust propeller shaft (14) length.
Tighten
All fasteners to specified torque. Refer to
3. Bolt (18) at the flange (17).
Mate the joint using reference marks.
Lubricate the Constant Velocity Joint (19). Refer
to Lubrication later in this section.
4. Skid plate, if used.
Tighten
All fasteners to specified torque. Refer to
Specifications later in this section.
LUBRICATION
The front axle propeller shaft found on four-wheel drive
vehicles requires a special lubricant at two locations: the
constant velocity joint, and the slip yoke.
Constant Velocity Joint (C/V Joint)

The constant velocity (C/V) joint, located at the transfer
case end of the front propeller shaft, must be lubricated
p e rio d ic a lly w ith a s p e c ia l lu b ric a n t, 1050679 or
equivalent. If the lubrication fitting cannot be seen from
beneath the vehicle refer to figure 9 which shows how the
C/V joint may be lubricated from above, with a special
adapter J-25512-2 on the end of a flex hose (figure 9).
Slip Spline
Apply chassis lubricant at the slip spline grease fitting
until the grease begins to leave through the vent hole.
If the slip spline is dry or corroded, it may be necessary
to disconnect the propeller shaft from the vehicle, remove
the slip yoke, and wire brush the affected area. Wipe
clean before installation.
Figure 9Lubricating the Constant Velocity

Joint Fitting
SPECIFICATIONS
APPLICATION
P ropeller Shaft:
To Rear A xle (R etainer or S tra p ) .....................................
To Rear A x le ..........................................................................
Two Piece Propeller S h a ft-F ro n t
To Brake Hub S tu d s ............................................................
To Transm ission F lan ge /Y o ke ............................................
To Transfer Case Yoke (N u t)..............................................
C enter B earing Support:
To
TORQUE
FT. LBS.
MODEL
Nm
R, G, P
R, V, G300, P
2 0*
35
15*
26
R, G, P
V
27
20
27
20
15
20
P300
R
P
V
R
R, G
33
20
35
27
33
33
24
15
26
20
24
24
P
R, G, P
R, V, G300, P300
27
20
33
20
15
24
V
V100, 200
V300
100
20
20
74
15
15
P300
Two Piece P ropeller S h a ft-R e a r:
To Rear Axl
Propeller Shaft:
T o rq u e S pecification Is For Hex Head Bolt.
SPECIAL TOOLS
1.
2.
3.
4.
J-22610
3.
J-25512-2
J-25512
4.
J-33051
K e ysto n e C la m p P liers
CV P ro p s h a ft Lube G un
N ee dle P oint
D rive s h a ft W re nch
B-07708
REAR AXLE 4B1-1
SECTION 4B1
REAR AXLE
manual as indicated at appropriate locations by the term inology: NOTICE: See Notice on page 4B-1 of this section.
NOTICE: All rear axle fasteners are important attaching parts in that they could affect the performance o f vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part o f lesser
of all parts.
CONTENTS
SUBJECT
PAGE
Description................................................................................................................................................................... 4B1- 1
Rear Axle O p e ra tio n .............................................................................................................................................. 4B1- 1
Diagnosis of the Rear A xle........................................................................................................................................ 4B1- 2
Determining the Type of Noise..............................................................................................................................4B1- 2
On-Vehicle S e rv ic e .................................................................................................................................................... 4B1- 8
Rear Axle Assembly Replacement (All Axles)..................................................................................................... 4B1 - 8
Semi Floating Axle (81/2-91/2>lnch Ring Gear)......................................................................................................... 4B1 - 9
Axle Shaft, Oil Seal and Bearing Replacement................................................................................................... 4B1- 9
Brake Backing Plate Replacement........................................................................................................................4B1-11
Wheel Stud Replacem ent...................................................................................................................................... 4B1-11
Pinion Flange, Dust Deflector/Oil Seal Replacement.........................................................................................4B1-12
Full Floating Axle (93/4-101/2-lnch Ring Gear)......................................................................................................... 4B1-14
Axle Shaft Replacement.................................................................. ......................................................................4B1-14
Hub And Drum Assembly Replacement............................................................................................................... 4B1-14
Wheel Bearing/Cup Replacement..........................................................................................................................4B1-15
Non-Demountable Type Drum Replacement................................................................ .......................................4B1-16
Wheel Bolt Replacement........................................................................................................................................ 4B1-16
Bearing A djustm e n t................................................................................................................................................4B1-16
Pinion Oil Seal/Companion Flange Replacement............................................................................................... 4B1-17
Full Floating Axle (12-Inch Ring G e a r)................................................................................................................... 4B1-18
Axle Vent Replacement.......................................................................................................................................... 4B1-18
Axle Shaft Replacem ent........................................................................................................................................ 4B1-18
Bearing Adjustm ent................................................................................................................................................ 4B1 -18
Drive Pinion Oil Seal R eplacem ent..................................................................................................................... 4B1-19
S pe cifica tio n s.............................................................................................................................................................4B1-20
Special T o o ls ...............................................................................................................................................................4B1-21
DESCRIPTION
Light duty trucks use various rear axles. These axles
can be identified by ring gear size in inches, by m anufac
turer (Corporate, Dana, or Rockwell) and by the type of
axle shaft used (Semi-Floating or Full Floating). Corporate
axles include the 8 V2 , 91fe and 101/2-inch ring gear axles.
Dana also supplies a 101/2-inch ring gear axle as well as a
9 3/4-inch ring gear axle. The 12-inch ring gear axle is sup
plied by Rockwell, and uses rear wheel disc brakes.
REAR AXLE OPERATION

A basic differential has a set of four gears. Two are
called differential side gears and the other two are
differential pinion gears. Some differentials have more
than two pinions. Each side gear is splined to an axle
shaft, therefore each axle shaft must turn when its side
gear rotates.
The d iffe re n tia l p in io n g ea rs are m ou nte d on a
differential pinion shaft, and the gears are free to rotate on
this shaft. The pinion shaft is fitted into a bore in the
differential case and is at right angles to the axle shafts.
Power flow through the differential is as follows: the
drive pinion rotates the ring gear. The ring gear, being
bolted to the differential case, rotates the case. The
differential pinion, as it rotates with the case, forces the
pinion gears against the side gears. When both wheels
have equal traction, the pinion gears do not rotate on the
pinion shaft because the input force on the pinion gear is
equally divided between the two side gears. Therefore,
the pinion gears revolve with the pinion shaft, but do not
4B1-2 REAR AXLE

rotate around the shaft itself. The side gears, being
splined to the axle shafts and in mesh with the pinion
gears, rotate the axle shafts.
If a vehicle were always driven in a straight line, the ring
and pinion gears would be sufficient. The axle shaft could
then be solidly attached to the ring gear and both driving
wheels would turn at equal speed.
However, if it became necessary to turn a corner, the
tires would scuff and slide because the outside wheel
would travel further than the inside wheel. To prevent tire
scuffing and sliding, the differential becomes effective
and allows the axle shafts to rotate at different speeds.
When the vehicle turns a corner, the outer rear wheel
must turn faster than the inner wheel. The inner wheel
turns slower than the outer wheel and slows its rear axle
side gear (as the axle shaft is splined to the side gear)
and the rear axle pinion gears will roll around the slowed
rear axle side gear, driving the other rear axle side gear
and wheel faster.
LOCKING REAR AXLE

Eaton Locking Differential
T he lo c k in g re a r d iffe re n tia l a llo w s fo r n o rm a l
differential function as indicated in the standard rear axle
description. Additionally, the locking rear differential uses
m u lti- d is c c lu tc h p a c k s and a s p e e d s e n s itiv e
engagem ent mechanism that locks both wheels together
if one wheel should spin excessively during slow vehicle
operation.
Under light loads, the clutch plates alone tend to lock

axle shafts to the differential case, and therefore, each
other. This is due prim arily to the gear separating load
developed on the right side clutch pack. This induced
clutch torque capacity resists motion between the side
gear and the rear axle differential case. The axle shaft
torques developed when turning a corner will overcome
this capacity and allow differentiation. Also, heavier
throttle application will cause differential, but this starts
the full-lock feature of the unit.
Full locking is accom plished through the use of a
heavyweight governor m echanism , cam system , and
multi-disc clutch packs. The flyweights on the governor
m echanism move outward to engage a latching bracket
w h e n e v e r th e w h e e l-to -w h e e l s p e e d v a rie s by
approximately 100 rpm or more. This action retards a cam
which, in turn, compresses the multi-disc clutch packs
locking both side gears to the case. The 100 rpm
w he el-to -w he e l speed allo w s fo r co rn e rin g w ith o u t
differential lock-up.
At vehicle speeds above approximately 32.2 km/h (20
mph), the latching bracket overcomes a spring preload
and swings away from the flyweights. At this vehicle
speed or greater, the differential will not lock, as the
added traction is generally not required.
All gear axle parts of vehicles equipped with the locking
rear axle are interchangeable with those equipped with
the conventional rear axle, except for the case assembly.
DIAGNOSIS OF THE REAR AXLE

The most essential part of rear axle service, as with any
m echanical repair, is proper diagnosis of the problem,
and, in axle work one of the most difficult areas to diag
nose is noise. Locating a broken axle shaft, or broken
differential gear, presents little or no problem, but, locat
ing and isolating axle noise can be an entirely different
matter.
Degree of Noise
Any gear driven unit, especially an automotive drive
axle where engine torque m ultiplication occurs at a 90
degree turn in the drive line, produces a certain amount of
noise. Therefore, an interpretation must be made for each
vehicle to determine w hether the noise is normal or if a
problem actually exists. A normal amount of noise must
be expected and cannot be elim inated by conventional
repairs or adjustment.
Acceptable noise can be defined as a slight noise heard
only at a certain speed or under unusual or remote
conditions. For example, this noise tends to reach a
peak at speeds from 40 to 60 miles per hour (60 to 100
km/h) depending on road and load conditions, or on gear
ratio and tire size. This slight noise is in no way indicative
of trouble in the axle assembly.
D riv e lin e n o is e s m a y b a ffle e ven th e b e s t
d ia g n o s tic ia n . V e h ic le n o is e s co m in g from tire s ,
transmission, propeller shaft, universal joints, and front or
rear wheel bearings, are often mistaken for axle noise.
Such practices as: raising tire pressure to eliminate tire
noise (although this will not silence tread noise of mud

and snow tires), listening for the noise at varying speeds
and road surfaces, on drive, float, and coast conditions
will aid in locating the source of alleged axle noises. Thus,
every effort should be made to isolate the noise to a
specific drive line component instead of m aking a random
guess that could be a costly waste of time.
DETERMINING THE TYPE

OF NOISE
External Noise
When a rear axle is suspected of being noisy, it is
advisable to make a thorough test to determ ine whether
the noise originates in the tires, road surface, front wheel
bearings, engine, transm ission, or rear axle assembly.
N oise w h ic h o rig in a te s in o th e r p la c e s c a n n o t be
corrected by adjustment or replacement of parts in the
rear axle assembly.
Road Noise Some road surfaces, such as brick or

rough-surfaced concrete, cause noise which may be
mistaken for tire or rear axle noise. Driving on a different
type of road, such as smooth asphalt or dirt, will quickly
show whether the road surface is the cause of noise.
Road noise usually is the same on drive or coast.
Tire NoiseTire noise may easily be mistaken for rear
axle noise, even though the noisy tires may be located on
the front wheels. Tires worn unevenly, or having surfaces
on non-skid divisions worn in saw-tooth fashion, are
REAR AXLE 4B1-3

usually noisy and may produce vibrations which seem to
originate elsewhere in the vehicle. This is particularly true
with low tire pressure.
Tire Noise TestTire noise changes with different
road surfaces, but rear axle noise does not. Temporarily
inflating all tires to 345 kilopascals (50 pounds per square
inch) pressure, for test purposes only will materially alter
noise caused by tires but will not affect noise caused by
the rear axle. Rear axle noise usually stops when
coasting at speeds under 30 miles per hour; however, tire
noise continues but with lower tone as the vehicle speed
is reduced. R ear axle noise usually changes when
comparing p u ll and coast but tire noise remains
about the same.
Engine and Transmission NoisesSom etim es a
noise which seems to originate in the rear axle is actually
caused by the engine or transm ission. To determ ine
w h ich u n it is a c tu a lly c a u s in g th e noise, o b se rve
approximate car speeds and conditions under which the
noise is most pronounced; then stop the vehicle in a quiet
place to avoid interfering noises. With the transm ission in
neutral, run the engine slowly up and down through the
engine speeds corresponding to the vehicle speed at
which the noise was most pronounced. If a sim ilar noise
is produced with the vehicle standing, it is caused by the
engine or transm ission and not the rear axle.
Front Wheel Bearing Noise Loose or rough front
wheel bearings will cause noise which may be confused
with rear axle noise; however, front wheel bearing noise
does not change when com paring p ull and coast.
Light application of the brake, while holding the vehicle
speed steady, will often cause the wheel bearing noise to
dim inish, as this takes some weight off of the bearing.
Front wheel bearings may be easily checked for noise by
jacking up the wheels and spinning them, and also by
shaking the wheels to determ ine if the bearings are
excessively loose.
Body Boom Noise or VibrationObjectional body
boom noise or vibration at 5 5 -6 5 mph (90-100 km/h) can
be caused by an unbalanced propeller shaft. Excessive
looseness at the spline can contribute to this unbalance.
O ther items that may also contribute to the noise
problem are as follows:
1. Undercoating or mud on the shaft, causing unbalance.
2. Shaft or companion flange balance weights missing.
3. Shaft damage, such as bending, dents, or nicks.
4. Tire-type roughness. Switch tires from a known good
vehicle to determine a tire fault.
If, after making a comprehensive check of the vehicle,
all indications point to the rear axle, further diagnostic
steps are necessary to determine the axle components at
fa u lt. True rear axle noise g e n e ra lly fa lls into two
categories: gear noise and bearing noise.
Rear Axle Noises

If a careful test of the vehicle shows that the noise is not
caused by external items, it is then reasonable to assume
that noise is caused by the rear axle assembly. Test the
rear axle on a smooth level road to avoid road noise. It is
not advisable to test the rear axle for noise by running
with the rear wheels jacked up.
Noise in the rear axle assem bly may be caused by a
faulty propeller shaft, faulty rear wheel bearings, faulty
d iffe re n tia l or p in io n sh a ft b e a rin g s , m is a lig n m e n t
Figure 1Causes of Gear Noise

between two U-joints, or worn differential side gears and
pinions; noise may also be caused by a mism atched,
improperly adjusted, or scored, ring and pinion gear set.
Rear Wheel Bearing NoiseA rough rear w heel

bearing produces a vibration or growl which continues
with the vehicle coasting and the transm ission in neutral.
A brinelled rear wheel bearing causes a knock or click
approximately every two revolutions of the rear wheel,
since the bearing rollers do not travel at the same speed
as the rear axle and wheel. W ith the rear wheels jacked
up, spin the rear wheels by hand while listening at the
hubs for evidence of a rough or brinelled wheel bearing.
Differential Side Gear and Pinion Noise Differentia!
side gears and pinions seldom cause noise since their
movement is relatively slight on straight ahead driving.
Noise produced by these gears will be most pronounced
on turns.
Pinion Bearing failures can be distinguished because
th e y rotate at h ig h e r sp ee ds than d iffe re n tia l side
bearings and axle shaft bearings. Rough or brinelled
pin ion b e a rin g s p ro du ce a c o n tin u o u s low p itch e d
w hirring or scraping noise starting at a low speed.
Side Bearings produce a constant rough noise pitched
lower than pinion bearing noise. Side bearing noise may
also fluctuate in the above rear wheel bearing test.
Gear Noise
There are two basic types of gear noise. The first type is
produced by broken, bent, or forcibly damaged gear teeth
and is usually quite audible over the entire speed range
and presents no particular problem in diagnosis. For
example, hypoid gear tooth scoring generally results from
the following: insufficient lubricant, im proper break-in,
improper lubricant, insufficient gear backlash, im proper
ring and pinion gear alignment, or loss of drive pinion nut
torque. The scoring will progressively lead to complete
erosion of the gear tooth, or gear tooth pitting and then
eventual fracture if the initial scoring condition is not
corrected (figure 1). A nother cause of hypoid tooth
fracture is extended overloading of the gear set which will
produce fatigue fracture, or shock loading which will
result in sudden failure.
4B1-4 REAR AXLE
ABRASIVE ROLLER WEAR
ABRASIVE STEP WEAR
Pattern on race s and ro lle rs ca u se d by fin e

abrasives.
noisy.
Pattern on ro lle r e n d s c a u s e d by fin e a b ra

sives.
noisy.
GALLING
ETCHING
M etal sm e a rs on ro lle r e n d s due to overheat,

lu b ric a n t fa ilu re o r o ve rlo a d .
R eplace b e a rin g , c h e c k se a ls and c h e c k fo r
B e aring s u rfa c e s a pp ea r gray o r g ra y is h b la c k

in c o lo r w ith related e tc h in g aw ay o f m a te ria l
u s u a lly at ro lle r s p a c in g .
R eplace b ea rin gs, c h e c k s e a ls and c h e c k fo r
B-09194
Figure 2Diagnosis of Tapered Roller Bearings
REAR AXLE 4B1-5
BENT CAGE
C age dam ag ed d u e to im p ro p e r h a n d lin g o r
to o l usage.
R ep lace b ea rin g.
BENT CAGE
C age d a m a g e d d u e to im p ro p e r h a n d lin g o r
to o l usage.
R ep lace b e a rin g .
CAGE WEAR
INDENTATIONS
W ear a ro u n d o u ts id e d ia m e te r o f ca ge and
ro lle r p o c k e ts ca u se d by a b rasive m a te ria l
and in e ffic ie n t lu b ric a tio n .
C lean related p a rts and h o u s in g s .
C h e c k se a ls and re p la ce b e a rin g s.
S u rfa c e d e p r e s s io n s o n ra c e a nd r o lle r s
ca u s e d by hard p a rtic le s o f fo re ig n m a te ria l.
C lean all p a rts and h o u s in g s . C h e c k s e a ls and
rep la ce b e a rin g s if ro u g h o r noisy.
B-09195
4B1-6 REAR AXLE
FRETTAGE
SMEARS
C o rro s io n se t up by sm a ll relative m o ve m e n t
o f p a rts w ith no lu b ric a tio n .
R eplace b e a rin g . C lean related parts. C h e c k
seais and c h e c k fo r p ro p e r lu b ric a tio n .
S m e a rin g o f m eta l due to s lip p a g e . S lip p a g e

c a n be c a u s e d by p o o r f it s , lu b r ic a tio n ,
o v e rh e a tin g , o ve rlo a d s o r h a n d lin g dam age.
R e p la c e b e a rin g s , c le a n re la te d p a rts and
c h e c k fo r p ro p e r fit and lu b ric a tio n .
STAIN DISCOLORATION
HEAT DISCOLORATION
D is c o lo ra tio n can range fro m lig h t b row n to

b la c k ca u se d by in c o rre c t lu b ric a n t o r m o is
ture.
Re-use b e a rin g s if s ta in s can be rem oved by
lig h t p o lis h in g o r if no e vid e n ce o f o ve rh e a t
ing is o bse rve d .
H eat d is c o lo ra tio n can range fro m fa in t y e l

low to d ark b lu e re s u ltin g fro m o ve rlo a d o r in c o rre c t lu b ric a n t.
E xce ssive heat can ca u s e s o fte n in g o f races
o r rollers. To c h e c k fo r lo s s o f te m p e r on
C h e ck se a ls and related p a rts fo r dam age.
races o r ro lle rs a s im p le file te s t m ay be

m ade. A file dra w n o ver a te m p e re d part w ill
grab and c u t m eta l, w he re a s, a file d ra w n over
a hard part w ill g lid e re a d ily w ith no m eta l
c u ttin g .
R eplace b e a rin g s if o ver h e a tin g d am ag e is
in d ic a te d . C h e c k se als and o th e r parts.
F-00531
REAR AXLE 4B1-7
MISALIGNMENT
O u te r race m is a lig n m e n t d ue to fo re ig n o b
je c t.
C lean related p a rts and re p la ce b ea rin g. M ake
CRACKED INNER RACE

Race cra c k e d d u e to im p ro p e r fit, c o c k in g , o r
p o o r b e a rin g seats.
R eplace b e a rin g and c o rre c t b e a rin g se ats.
su re races are p ro p e rly seated.
FATIGUE SPALLING
F la k in g o f s u rfa c e m e ta l re s u ltin g fro m fa
tig u e .
R ep lace b e a rin g , clea n all related parts.
BRINELLING
S u rfa c e in d e n ta tio n s in racew ay c a u se d by
ro lle rs e ith e r u n d e r im p a c t lo a d in g o r v ib ra
tio n w h ile th e b e a rin g is n o t ro ta tin g .
R eplace b e a rin g if rou gh o r noisy.
B-09860
4B1-8 REAR AXLE

Differential pinion and side gears rarely give trouble.
Common causes of differential failure are shock loading,
extended overloading, and seizure of the differential
pinions to the cross shaft resulting from excessive wheel
spin and consequent lubrication breakdown. The second
type of gear noise pertains to the mesh pattern of the gear
te e th . T h is fo rm of a b n o rm a l g e a r n o ise can be
recognized because it produces a cycling pitch (whine)
and will be very pronounced in the speed range at which
it occurs, appearing under either drive, or flo at or

coast conditions. Drive is acceleration or heavy pull.
Coast is with a closed throttle and the vehicle in gear
and flo at is using just enough throttle to keep the
vehicle from driving the engine; the vehicle slows down
gradually but the engine still pulls slightly. Gear noise
tends to peak in a narrow speed range or ranges, and will
tend to remain constant in pitch. Bearing noise will vary in
pitch with vehicle speeds.
Refer to figures 2 through 5 for bearing diagnosis.
ON-VEHICLE SERVICE
REAR AXLE ASSEMBLY
REPLACEMENT (ALL AXLES)
Raise the vehicle on a hoist and support the axle
assembly with a suitable lifting device.
For 93/4-inch ring gear and 101/2-inch ring gear axles,
raise the vehicle and place jack stands under the
frame side rails for support.
Drain the lubricant from the axle housing.
1. Propeller shaft. Refer to PROPELLER SHAFT (SEC.
4A).
Tie the p ro p e lle r sh a ft to a side rail or
crossmember.
Tape the bearing cups to prevent loss of the
rollers.
2. Wheel and brake drum or hub and drum assembly.
3. Parking brake cable from the lever and at the brake
flange plate.
4. Hydraulic brake lines from the connectors.
5. Shock absorbers from the axle brackets.
6 . V e n t h o s e f r o m t h e a x l e v e n t f it t in g if u s e d .
7. Height sensing and brake proportional valve linkage if

used.
8. Stabilizer shaft if used.
Support the assembly with a hydraulic floor jack.
9. Nuts and washers from the U-bolts.
10. U-bolts, spring plates and spacers from the axle
assembly.
Lower the jack and the axle assembly.
hM j Install or Connect
1. Axle assembly under the vehicle.
Align the axle assembly with the springs.
2. Spacers, spring plates and U-bolts to the axle
assembly.
Raise the axle assembly.
3. Washers and nuts to the U-bolts.
Thread the nuts on firmly.
Adjust alignment of semi-float axles.
4. Stabilizer shaft if used.
5. Height sensing and brake proportional valve linkage if
used.
6. Vent hose to the axle vent fitting if used.
7. Shock absorbers to the axle brackets.
8. Hydraulic brake lines to the connectors.
9. Parking brake cable to the lever and the flange plate.
10. Wheel and brake drum or hub and drum assembly.
11. Propeller shaft.
NOTICE: See N otice on page 4B1-1 of this
section.
T ig h te n
All fasteners to Specifications later in this section.
| ? | Im portant
Check axle lubricant level at the filler plug hole.
Lubricate as needed.
Bleed the brake system, check operation and adjust
if necessary. Refer to BRAKES (SEC. 5).
Check axle and brake operation.
Check for fluid leaks and road test the vehicle.
REAR AXLE 4B1-9
SEMI-FLOATING AXLE
(8 V2- AND 91/2-INCH RING GEAR)
10 . Drum
11 . B o lt
1 2 . S h aft
13.
14.
15.
16.
17.
18.
19.
Lock
Seal
B e aring
H o u s in g
C lip
B o lt
C a rrie r C over
F-00636
Figure 6Axle Shaft and Housing Components
AXLE SHAFT, OIL SEAL AND

BEARING REPLACEMENT
Clean dirt from around the carrier cover.
++
1.
2.
3.
4.
5.
6.
7.
8.

Tools Required:
J-2619-01 Slide Hammer with Adapter
J-23689 Axle Shaft Bearing Remover (large
shaft)
J-29712 Axle Shaft Bearing Remover (91/2-inch
ring gear)
Brake drum.
C arrier cover (19).
Catch the oil in a drain pan.
Remove gasket material if used.
Screw (A) (figures 7 and 8).
Pinion shaft (B).
Remove the shaft from the case on vehicles
without a locking differential.
With a locking differential remove the shaft (B)
part way and rotate the case until the pinion
shaft touches the housing (figure 9).
Use a screwdriver or similar tool to enter the
case and rotate the lock until it aligns with the
thrust block (figure 10).
Lock (13) (figure 11).
Push the flange of the axle shaft towards the
differential. Do not force or hammer the shaft to
move the shaft.
Remove the lock from the button end of the axle
shaft.
Axle shaft (12).
Slide the axle shaft out, being careful not to
damage the seal.
Seal (14) using J-23689.
9. Bearing (15).
Use J-23689 for 8 1/2-inch ring gear axle or
J-29712 for 9 1/2-inch ring gear to pull the bearing
from the axle.
Insert the tool into the axle bore so that it grasps
behind the bearing (15) (figure 12). Tighten the
nut and washer against the face of the bearing
(15).
Inspect
All parts. Replace as necessary.

Tools Required:
J-21128 Axle Shaft and Pinion Oil Seal Installer
J-23690 Axle Shaft Bearing Installer
4B1-10 REAR AXLE
J-29709 Axle Shaft Bearing Installer (9 1/2-inch

ring gear)
J-29713 Axle Shaft Seal Installer (9 1/2-inch ring
gear)
Lubricate the axle cavity between the seal (14)
lips and the bearing (15) with wheel bearing
lu b ric a n t. R efer to M A IN T E N A N C E AND
LUBRICATION (SEC. OB).
1. Bearing (15).
Use J-23690 for the 8 1/2-inch gear axle and
J-29709 for the 9 1/2-inch ring gear axle.
Bearing (15) into the axle (16) housing until the
tool bottoms against the tube. Refer to figure 13.
2. Seal (14).
Use J-21128 for 8 1/2-inch ring gear axle and
J-29713 for the 9 1/2-inch ring gear axle.
Drive the tool into the bore until the seal (14)
bottoms flush with the end of the tube (figure 14).
3. Axle shaft (12).
Be careful not to damage the seal (14) when
inserting the axle shaft ( 12).
B. P in io n S h a ft
E. T h ru s t B lo c k
F. S id e G ear (L o c k in g
D iffe re n tia l)
G. L ock (C-Lock)
H. S h a ft
F-00640
Figure 10Aligning the Lock
F-00642
Figure 12Removing the Bearing and Seal
REAR AXLE 4B1-11

8. Carrier cover (19).
9. Bolts (18) and clip (17).
Tighten bolts (18) in a crosswise pattern.
10. Brake drum.
11. Wheel and tire assembly.
Lower the vehicle.
12. Axle lubricant. Fill to the filler plug hole level. Refer to
BRAKE BACKING PLATE

REPLACEMENT
1. Wheel, tire and brake drum.
2. Axle shaft. Refer to Axle Shaft R eplacem ent
earlier in this section.
3. Brake line from the cylinder inlet.
Slide the axle shaft (12) into place allowing the
splines to engage the differential side gear (F)
figure 10.
4. Lock (13).
Without locking differential:
Place the lock on the button end of the axle shaft
(12), then pull the shaft flange outward to seat
the lock in the differential side gear.
With locking differential.
Keep the pinion shaft partially withdrawn (figure
9).
Place the lock in the position shown in figure 10.
Pull the shaft flange outward to seat the lock in
the differential side gear.
5. Pinion shaft (figure 8).
Align the hole in the pinion shaft with the screw
hole in the differential case.
6. Screw (A).
Tighten
Screw to 34 N m (25 ft. lbs.).
7. Carrier cover gasket or RTV (if used).
4. Brake com ponents from the backing plate. Refer to

BRAKES (SEC. 5).
5. Bolts and washers from the axle.
6. Backing plate.
Install or Connect
1. Backing plate to the axle.
2. Bolts and washers to the plate.
3. Brake com ponents to the backing plate. Refer to
BRAKES (SEC. 5).
4. Brake line to the cylinder inlet.
Refer to BRAKES (SEC. 5) for bleeding and
adjustment procedure.
5. Axle shaft. Refer to Axle Shaft Replacement earlier
in this section.
WHEEL STUD REPLACEMENT

Raise the vehicle on a hoist and allow the axle to
hang free.
Tool Required:
J-6627-A Wheel Stud Remover
Wheel, tire and brake drum.
Stud from the axle flange using J-6627-A (figure 15).
Install or Connect
1. Stud in the axle flange hole. Refer to figure 15.
Start the new stud into the axle flange hole by
pressing firmly with your hand.
Thread on a lug nut with the flat side to the
vehicle.
Tighten the lug nut and draw the stud head into
the rear of the flange.
Thread the lug nut off.
Lower the vehicle.
4B1-12 REAR AXLE
PINION FLANGE, DUST

DEFLECTOR/OIL SEAL
REPLACEMENT
|+-+| Remove or Disconnect

Tool Required:
J-8614-01
Remover
C om panion Flange H older and
1. Propeller shaft from the axle.

Tie the pro pe lle r shaft to a fram e rail or
crossmember.
| l j | | Measure
The torque required to rotate the pinion (figure
16). R e c o rd th e to rq u e v a lu e fo r la te r
reference.
Figure 16Measuring Pinion Rotating Torque
Im portant
Scribe a line on the pinion stem, pinion nut and
the companion flange and record the number of
exposed threads on the pinion stem. Use the
scribed reference and the exposed threads as a
reinstallation guide (figure 17).
Nut using J-8614-01.
Position J-8614-01 on the flange so that the four
notches on the tool face the flange (figure 18).
Flange using J-8614-01
Use the special nut and forcing screw to remove
the flange (figure 19).
Oil seal. Use a screw driver to pry the seal out of the
bore.
I?
Inspect
The pinion flange for a smooth oil seal surface,

for worn drive splines, dam aged ears and for
smoothness of the bearing contact surface.
Dust deflector.
Figure 18Removing the Drive Pinion Nut
REAR AXLE 4B1-13
Tap the deflector from the flange if replacement

is necessary.
Clean up the stake points on the flange.
Clean all foreign material from the contact area.
|-<-| Install or Connect

Tools Required:
J-8614-01 C om panion Flange H older and
Remover
J-22388 Pinion Oil Seal Installer (9 1/2-inch ring
gear)
J-22804-1 Pinion Oil Seal Spacer
Measure
The rotating torque of the pinion and
compare with the torque recorded earlier
(figure 16).
Tighten
The p in io n nut in a d d itio n a l s m a ll
increments until the torque necessary to
rotate the pinion exceeds the original
recorded value by 0.35 N m (3 in. lbs.).
4. Propeller shaft.
Lower the vehicle and road test.
J-22836 Pinion Seal Installer (8 1/2-inch ring gear)

1. Dust deflector on the flange.
Stake new deflector at three new equally spaced
positions. Staking must be such that the seal
operating surface is not damaged.
2 . Oil seal.
Pack the cavity between the lips of the oil seal

with extreme pressure lithium-base lubricant.
Position the oil seal in the bore then place
J-22804-1 over the oil seal and flat against the
seal flange (figure 20 ).
Use J-22836 for the 8 1/ 2-inch ring gear or
J-22388 for the 9 1/2-inch ring gear to press the oil
seal into the bore (figure 20 ).
Turn J-22804-1 from installed position 180
degrees to assure proper installation against the
pinion flange.
Pack the cavity between the end of the pinion
s p lin e s and th e p in io n fla n g e w ith a
non-hardening sealer such as PERMATEX TYPE
A or equivalent.
3. Flange onto the pinion using J-8614-01.
Place washer and nut on the pinion threads and
tighten the nut to the original scribed position
using the scribe marks and exposed threads as a
reference (figure 21). DO NOT ATTEMPT TO
HAMMER THE FLANGE ONTO THE PINION

SHAFT.
Figure 21Installing the Pinion Flange
4B1-14 REAR AXLE
( 9 3/4-
FULL FLOATING AXLE

AND 101/2-INCH RING GEAR)
HUB AND DRUM ASSEMBLY
REPLACEMENT
+ + Remove or Disconnect (Figure 23)
Raise the vehicle until the wheel is free to rotate.
Tool Required:
J-2222-C Wheel Bearing Nut Wrench
1. Wheel and tire.
2. Axle shaft (52) as outlined earlier in this section.
3. Nut (40) use J-2222-C or retaining ring (56). Refer to
figure 24.
4. Lock (41) or key (57).
5. Adjusting nut (42, 58). Refer to figure 24.
6. Washer (43).
Figure 22Removing or Installing

Flange-to-Hub Bolts
AXLE SHAFT REPLACEMENT
7. Hub and Drum (48, 49).
Inspect
All parts and replace as necessary.
|<"*| Remove or Disconnect (Figures 22 and 23)

1. Bolts (55).
Rap the axle shaft (53) flange lightly with a soft
faced hammer to loosen the shaft.
Grip the rib on the axle shaft (53) flange with a
locking plier and twist, to start shaft removal.
2. Axle shaft (53) from the tube.
Clean
Axle shaft (53) flange. Remove old RTV or
gasket (51).
Outside face of the hub assembly.
I*
NOTICE: For steps 3, 4 and 5 see N o tice on

page 4B-1 o f this section.
Tool Required:
1. Hub and drum (48, 49) to the tube.
Be sure the bearings and the oil seal are
positioned properly.
Apply a light coat of high melting point EP
bearing lubricant to the contact surfaces and the
outside of the axle tube.
2. Washer (43). Tang into key way.
3. Adjusting nut (42, 58). Refer to figure 24.
Inspect

1. Axle shaft (53) with a gasket or RTV applied.
Be sure the sh aft sp lin e s mesh into the
differential side gear.
Align the axle shaft holes with the hub holes.
2. Bolts (55) figures 22 and 23.
Q\ Tighten
Bolts (35) to specified torque later in this section.
Adjusting nut (42, 58) to specified torque later

in this section w hile turning the hub.
4. Lock (41) or key (57).
Bend the tang to the flat of the adjusting nut (42)
or insert the key (57).
5. Nut (40) or retaining ring (56). Refer to figure 24.
N ut (40) to s p e c ifie d to rq u e la te r in th is
section.
6. Axle shaft (52) earlier in this section.
7. Wheel and tire.
Lower the vehicle.
REAR AXLE 4B1-15

A. C he vro let
B. Dana
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
N ut
Lock
A d ju s tin g N u t
W a sh er
O u te r B e a rin g
In n e r B e aring
O il Seal
D rum
H ub
S tud
G a sket
S h a ft
A x le S h a ft F lange
W a sh er
B o lt
Key
A d ju s tin g N ut
O u te r B e aring
In n e r B e aring
O il Seal
F-00647
Figure 23Full Floating Axle, Hub and Drum Assembly Components
WHEEL BEARING/CUP
REPLACEMENT
Raise the vehicle till the wheels are free to rotate.
Tools Required:
J-24426 Outer Wheel Bearing Cup Installer
1. Axle shaft (52) as outlined earlier in this section.
Figure 24Removing or Installing Bearing

Adjusting Nut
2 Hub and drum (48, 49) as outlined earlier in this

section.
3. Oil seal (47) or (62).
4. Inner bearing (46) or (61). Use a drift to remove the
bearing and cup.
5. Retaining ring (45) or (60).
Use snap ring pliers to remove the ring.
6. Outer bearing (44) or (59) using J-8092 with J-24426
(figure 25).
Drive the bearing (44, 59) and cup from the hub
Figure 25Removing the Outer Bearing and Cup
4B1-16 REAR AXLE

Clean
Old sealing com pound from the oil seal (47,
62) bore in the hub (49).
Bearing assem blies in a solvent using a stiff
brush to remove the old lubricant. Dry the
bearings with compressed air. Do not spin
them.
Lubricant from the axle housing and inside the
hub (49).
Gasket material from the hub (49), axle shaft
(52).
L*
Inspect
Bearings for wear, chipped edges or other

damage. Check for flat or rough spots on the
rollers.
Cups for pits and cracks.
Oil seal for wear or roughness. Replace parts
as necessary.
Figure 26Wheel Bolt Replacement

Tools Required:
J-8608 Pinion Bearing Cup Installer
J-24426 Outer Wheel Bearing Cup Installer
J-24427 Inner Wheel Bearing Cup Installer
J-24428 Axle Shaft Seal Installer
1. Outer bearing cup (44, 59) into the hub (49).
Drive the cup into the hub using J-8092 and
J-8608. Be sure J-8608 is installed upside
down on J-8092 so that the chamfer does not

contact the bearing cup. Drive the cup beyond
the retaining ring groove.
2. Retaining ring into the groove.
Drive the cup back onto the retaining ring using
J-24426.
3. Inner bearing cup using J-8092 and J-24427.
Drive the cup into place until it is seated against
the hub shoulder.
4. Inner bearing (46) or (61).
5. New oil seal using J-24428.
6. Hub and drum assembly.
7. Outer bearing (44) or (59).
A djust
Bearing preload. Refer to Bearing Adjustment.
8. Axle shaft (52).
NON-DEMOUNTABLE TYPE
DRUM REPLACEMENT
Construction of the non-demountable type drum
and hub assem bly is such that replacement cannot
be done with the hub assem bly installed on the
vehicle.
Raise the vehicle.
1. Hub and drum assembly. Refer to Hub and Drum
Assembly Replacem ent earlier in this section.
2. Retaining bolts, stud nuts or wheel studs.
Separate the drum, hub and oil deflector.
Press the wheel studs out of the drum. Replace

parts as necessary.
Install or Connect
1. Drum to the hub.
Make certain drain holes are in alignment.
2. Oil deflector to the drum.
Apply a light coating of sealing compound to the
oil deflector contact surface.
3. Retaining bolts, stud nuts or wheel studs.
Press the wheel studs into the drum.
WHEEL BOLT REPLACEMENT

Wheel bolts are serrated and may also be swaged in
place; however, replacement procedure remains the
same for both types of installation. Press the wheel
bolts out of the hub flange, then press new wheel
bolts into place, m aking sure of a tight fit. When
replacing all of the wheel bolts be sure that the hub
oil deflector is in position under the wheel bolt
heads. Refer to figure 26.
BEARING ADJUSTMENT
Make sure the brakes are fully released and do not
drag.
Check the wheel bearing play by grasping the tire at
the top and pulling and pushing back and forth, or
by using a pry bar under the tire. If the wheel
bearings are properly adjusted, movement of the
brake drum in relation to the brake flange plate will
be barely noticeable and the wheel will turn freely. If
the movement is excessive, adjust the bearings.

Tool Required:
Raise the vehicle until the wheel is free to spin.
1. Axle shaft (52). Refer to Axle Shaft Replacement
REAR AXLE 4B1-17
1. Key (57) if used or new lock (41).

Key (57) into the keyway and adjusting nut (58)
slot.
Bend the lock (41) tang to the flat of the adjusting
nut (42).
2. Retaining ring (56) or nut (40) if used.
Bend the lock (41) tang to the flat of the nut (40).
Be sure the retaining ring (56) is seated.
3. Axle shaft (52). Refer to Axle Shaft Replacement
PINION OIL SEAL/COMPANION

FLANGE REPLACEMENT
The pinion oil seal and the companion flange may
be replaced with the carrier assembly installed in
the vehicle.
Be sure the keyway, threads and adjusting nut
(42, 58) are clean and free of chips, burrs and
shavings.
2. Nut (40) or retaining ring (56).
Disengage the tang from the nut (40).
3. Lock (41) or key (57).
Tighten
Tools Required:
Remover
Raise the vehicle.
Propeller shaft. Refer to PROPELLER SHAFT (SEC.
4A).
Tie the pro pe lle r shaft to a fram e rail or
crossmember.
Im portant
Adjusting nut (42, 58) to 70 N m (50 ft. lbs.) using

J-2222-C (figures 27 and 28).
Be sure the bearings are seated and in contact with
the spindle shoulder.
Adjust
Nut (42, 58). Back the nut (42, 58) off until just loose,
but not more than one slot of the lock or the axle
spindle using J-2222-C. Align the adjusting nut (58)
slot with the keyway in the axle spindle.
Scribe a line on the pinion stem, pinion nut

and companion flange to be used as a guide
for reinstallation (figure 17).
Nut using J-8614-01 (figure 18).
Flange using J-8614-01.
Use the special nut and forcing screw to remove
the flange (figure 19).
4. Oil seal.
Pry the oil seal from the bore. Do not damage the
machined surfaces. Thoroughly clean foreign
material from the contact area.
Replace parts as necessary.
0 Install or Connect
J-2222 C
F-00863
Figure 28Wheel Bearing Nut Wrench
Tools Required:
Remover
J-24384 Pinion Oil Seal Installer
(Dana 101/2-inch ring gear axle).
J-24434 Pinion Oil Seal Installer
(Chevrolet 101/2-inch ring gear axle).
Oil seal into the bore using J-24384 or J-24434.
Lubricate the cavity between the new seal lips
with a high melting point bearing lubricant.
Flange using J-8614-01.
Use scribed marks for reinstallation.
Nut, use J-8614-01 (figure 18).
Use scribe mark as an installation reference.
Propeller shaft. Refer to PROPELLER SHAFT (SEC.
4A).
4B1-18 REAR AXLE
FULL FLOATING AXLE (12-INCH RING GEAR)

70.
71.
72.
73.
74.
75.
76.
77.
B o lt
W a sh er
H u b ca p
G a sket
A x le S h a ft
A x le H o u s in g
B racket
W heel B o lt
H ex B o lt
D e fle c to r
O il Seal
In n e r B e aring
Brake D isc
O u te r B earing
Spacer
86 . H ub
87. T h ru s t W a sh e r
88 . A d ju s tin g N u t
89. L ock W a sh er
90.
N ut
F-01012
78.
79.
80.
81.
82.
83.
84.
85.
Figure 29Rockwell 12-Inch Ring Gear Axle and Hub Components
AXLE VENT REPLACEMENT

A threaded type axle vent is used on the Rockwell
12-inch ring gear axle and must be replaced if the
vent cap is dam aged or missing.
Clean
The area around the axle vent.
Axle vent from the housing.
-4- Install or Connect

Axle vent to the housing.

Raise the vehicle and place jack stands under the
frame side rails.
1.
2.
3.
Tools Required:
Hub cap (72).
Thread J-8117 into the tapped hole on the axle shaft
(74) flange.
Axle shaft (74) using J-2619-01.
Clean
Old gasket material from the hub (86) and hub cap
(72) and the axle shaft (74) flange and m ating
surface in the hub (86).
+ + Install or Connect (Figure 29)

Tools Required:
1. Axle shaft (74).
Tap the axle shaft (74) into position using
J-2619-01.
Index the axle shaft (74) splines into the hub (86)
splines.
2. Gasket (73).
3. Hub cap (72).
4. Washers (71) and bolts (70).
BEARING ADJUSTMENT
Make sure the brakes are fully released and do not
drag.
Check the wheel bearing play by grasping the tire at
the top and pulling and pushing back and forth, or
by using a pry bar under the tire. If the wheel
bearings are properly adjusted, movement of the
hub o r d is c w ill be b a re ly n o tic e a b le . If the
m ovement is excessive, adjust the bearings.
REAR AXLE 4B1-19

Tool Required:
J-25510 Wheel Bearing Nut Wrench
Raise the vehicle until the wheel is free to
spin.
Axle shaft (74). Refer to Axle Shaft Replacement.
Nut (90) using J-25510.
Release the tang.
Lock washer (89).
Adjust
Nut (88) using J-25510. Tighten the nut (88)
while the hub is rotating to 68 N-m (50 ft. lbs.).
Make sure the bearing surfaces are in contact
and then back the nut (88) off 1/s turn.
E3
1. Lock washer (89).

Bend a tang over a flat of the adjusting nut (88).
2. Nut (90) using J-25510.

Tighten the nut (90) to 339 N m (250 ft. lbs.).
Bend a long tang of the lock washer (89) over a
\ flat of the nut (90).
Axle shaft (74). Refer to Axle Shaft Replacement.
Lower the vehicle.
DRIVE PINION OIL SEAL

REPLACEMENT
E3
* l l Remove or Disconnect (Figure 30)

Tools Required:
Remover
Raise the vehicle.
4A).
Im portant
2.
3.
4.
5.
6.
Scribe a reference line on the pinion stem,

pinion nut and companion flange.
Cotter key (91) and nut (92) using J-8614-01.
Companion flange (94).
Bolts (97).
Oil seal retainer (95).
Oil seal (96).
Pry the oil seal (96) from the bore being careful
not to damage the machined surfaces.
Clean
The seal contact area.

Lubricate the cavity between the new seal (96) lips
with a high m elting point bearing lubricant. Refer to
MAINTENANCE AND LUBRICATION (SEC. 0B).
1. Oil seal (96) into the bore using a suitable tool.
Be sure the seal (96) bottoms against the

bore shoulder.
2. Oil seal retainer (95).
3. Bolts to the retainer (97).
91 .
92 .
93 .
94 .
C o tte r Key
N ut
P in io n S h a ft
C o m p a n io n F la n g e
95.
96.
97.
O il Seal R e ta in e r
O il Seal
B o lt
F-01013
Figure 30Drive Pinion Oil Seal Components

4. Companion flange (94) use the scribed reference
mark.
5. Nut (92) using J-8614-01.
Nut (92). Align the castellated nut with the hole

in the pinion shaft (93) stem and the reference
mark.
6. Cotter key (91).
4A).
4B-20 REAR AXLE
SPECIFICATIONS
TORQUES
8V2 " RING GEAR-
SEMI FLOATING
AXLE
Filler Plug
Lock Screw
Brake Backing
Plate
Axle Shaft to
Hub Bolts
Carrier Cover
Axle
Lubricant
Capacity
91/2" RING GEARSEMI FLOATING

AXLE
DANA
9% "-10 1fe" RING
GEAR AXLE-FULL
FLOATING
CHEVROLET
IOV2 " RING GEAR
AXLE-FULL
FLOATING
ROCKWELL
12" RING GEAR
AXLE-FULL
FLOATING
Nm
FT. LBS.
N-m
FT. LBS.
Nm
FT. LBS.
N-m
FT. LBS.
N-m
FT. LBS.
34
34
25
25
24
34
18
25
14
10
24
18
47
35
47
35
142
105
142
105
142
105
27
20
27
20
156
47
115
35
156
41
115
30
Liters
Pints
Liters
Pints
Liters
Pints
Liters
Pints
Liters
Pints
2.0
4.2
2.6
5.5
2.6
5.5
3.4
7.2
6.6
14.0
WHEEL BEARING ADJUSTMENT VALUES

RING GEAR
SIZE
93/4" Ring Gear
10 V2 " Ring Gear
12" Ring Gear
BEARING ADJUSTING
NUT TORQUE*
ADJUSTING NUT
BACKOFF*
OUTER LOCKNUT
TORQUE
68.0 N-m 50 ft. lbs.

68.0 N-m 50 ft. lbs.
68.0 N-m 50 ft. lbs.
* *
88.1 N-m 65 ft. lbs.
1/s Turn
RESULTING
BEARING
ADJUSTMENT
0.0254 to 0.254 mm
.001 to .010 inch
339.0 N-m 250 ft. lbs.
End Play
With wheel rotating.

**Back-off the nut and retighten to 47 N m (35 ft. lbs.). Then back the nut off V* turn.
TYPE OF
BEARING
TAPERED
ROLLER
REAR AXLE 4B1-21
1.
J-24428
11.
J-6627-A
12.
2.
j-
J-8092
J-23689
14.
J-5853-B
3.
15.
cm m
J-21128
16.
((((( 55 )
J-23690
17.
(1
J-29709
J-8614-01
4.
J-2919-01
5. cnglt
1 8 -
6.
7.
24434
r ~
l ( a
j *2 9 7 1 3
J-2222-C
J-24426
20.
J-22804-1
8.
J-24427
9.
J-8608
21. (J
J-22836
10.
J-24384
22.
J-25510
B-07587
4B1-22 REAR AXLE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
W heel Stud Remover

Driver Handle
Inch/Pound-Torque W rench
C om panion Flange H older and Remover
Slide H am m er w ith A dapter
O uter W heel Bearing Cup In staller
Inner W heel Bearing Cup In sta lle r
O uter Pinion Bearing Cup In sta lle r
Pinion Oil Seal In sta lle r
A xle Shaft Seal In sta lle r
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Pinion O il Seal In sta lle r

W heel Bearing Inner Cup In sta lle r
A xle Shaft Bearing Remover
A xle Shaft and Pinion Oil Seal In s ta lle r
A xle Shaft Bearing In sta lle r
A xle Shaft Bearing In sta lle r (91/2-lnch Ring Gear)
A xle Shaft Seal In sta lle r (91/2-lnch Ring Gear)
Pinion O il Seal In sta lle r (91/2-lnch Ring Gear)
Pinion O il Seal Spacer
Pinion Seal In sta lle r (81/2-lnch Ring Gear)
B-07586
FRONT AXLE 4C-1
SECTION 4C
FRONT AXLE
manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 4C-1 of this section.
NOTICE: All front axle fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part
of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ........................................................................................................................................................................................ 4C-1

D iag no sis Of The F ront A x l e ...................................................................................................................................................... 4 C -2
Road T e s t ...................................................................................................................................................................................... 4 C -2
Tire* N o is e s .................................................................................................................................................................................... 4 C -2
E ngine o r Exhaust N o is e s .........................................................................................................................................................4 C -2
T est For Wheel Bearing N o is e ................................................................................................................................................4 C -2
T est For D iffe re ntia l B earing N o is e ...................................................................................................................................... 4 C -2
T est For Pinion Bearing N o is e ................................................................................................................................................4 C -2
O n -V ehicle S e r v ic e .........................................................................................................................................................................4 C -2
A xle S haft R e p la c e m e n t........................................................................................................................................................... 4 C -2
F ront Axle A ssem bly R e p la c e m e n t...................................................................................................................................... 4 C -3
A xle J o in t C om ponent R e p la c e m e n t.................................................................................................................................... 4 C -4
L o ckin g Hub C om po n en t R e p la c e m e n t........................................................................................... .................................... 4 C -4
A u to m a tic Hub To The W heel A d ju s tm e n t.........................................................................................................................4 C -7
M anual Locking Hub R e p la c e m e n t.........................................................................................................................................4 C -7
Manual Locking Hub R ebuild P ro c e d u re ............................................................................................................................. 4 C -8
S p e c ific a tio n s ..................................................................................................................................................................................4 C -8
S pecial T o o ls .................................................................................................................................................................................... 4 C -8
DESCRIPTION
The front axle is a hypoid gear axle unit equipped with
steering knuckles and an automatic or manual locking
hub. The V-10/15 and 20/25 models use a Chevrolet front
axle having an 8 1/2-inch ring gear axle rated at 3600
pounds for the V-10/15 and 3800 pounds for the V-20/25. A
Dana (60 Series) axle is used on the V-30/35 model and is
rated at 4500 pound capacity. The Dana axle has a 9 3/4inch ring gear. Automatic hub locks are used on all
models to engage the hub whenever four-wheel drive is
selected. A manual locking hub is used on the V-30/35
model only and must be engaged manually whenever
four-wheel drive is selected.
4C-2 FRONT AXLE
DIAGNOSIS OF THE FRONT AXLE

ROAD TEST
Check tires for irregular wear.

Check tire pressure.
Check axle lubricant level.
Drive to warm up the front axle.
Test at various speeds in drive, float, coast and
while cornering.
Verify that the hubs are locked.
TIRE NOISES
Change the tire pressure to minimize noises.

Drive over different road surfaces.
Smooth black-top minimizes tire noise.
Cross switch the tires, if necessary.
Snow tire treads and studs cause added noises.
ENGINE OR EXHAUST NOISES

Drive slightly above the speed where the noise occurs,
place transmission in neutral.
Let the engine speed drop to idle.
Stop the vehicle.
Run the engine at various speeds.
TEST FOR WHEEL BEARING NOISE

Drive the vehicle at low speed on a smooth road.
Turn the vehicle to develop left and right motions,
traffic permitting.
Noise should change due to cornering loads.

Jack-up wheels to verify roughness at the wheels.
TEST FOR DIFFERENTIAL

BEARING NOISE
Drive the vehicle at low speed on a smooth road.

Constant low pitch bearing noise may be heard.
Noise should not change in reversing turns.
The noise pattern should vary with the wheel speed.
*TEST FOR PINION BEARING

NOISE
Rough running or a whine noise should increase
with speed.
Noise pitch should be higher than differential noise.
Perform the test on a smooth road to m inimize tire
noises.
Perform test at various speeds in drive, float, and
coast.
Rear pin ion b earing noise m ay be lo u d e r on
acceleration.
Front p in ion b earing noise m ay be lo u d e r on
deceleration.
Gear noise tends to peak in a narrow speed range.
Bearing tests should be done in 2H (after 4H selection to
lock hubs). This removes the transfer case whine.
ON-VEHICLE SERVICE
Raise the vehicle.
1. Wheel and tire.
2. Brake caliper (40).
Im portant
Support the brake caliper (40) so as not to
stretch or dam age the brake hose.
3. Hub lock mechanism (20).
4. Rotor and hub (28).
5. Inner bearing (31) and seal (32).
6. Splash shield (41), brake bracket (39) and spindle (38).
7. Axle shaft (46).
gi Clean
Inner and outer wheel bearing (31, 26).
Hub and disc (28), spindle (38).
L9
Im portant
Lube the spindle bearing (37) and spindle (38).
Pack the inner and outer wheel bearing (31, 26).
NOTICE: For steps 3, 4 and 5, see N o tic e on
page 4 C - 1 of this section.

1. Seal (36) and spacer (35) to the axle shaft (46).
2. Axle shaft (46) into the housing (42).
3. Spindle (38) to the knuckle (44). Be sure the seal
(34) and outer deflector (33) are in place.
4. Brake bracket (39).
5. Splash shield (41).
New washers (48) and nuts (49) to the studs.
Torque the nuts (49) to 88 N-m (65 ft. lbs.).
6. Hub and disc (28).
Adjust the wheel bearings (26, 31). Refer to
FRONT SUSPENSION (SEC. 3C).
Inspect
7. Retainer (22) and ring (21).
8. Hub lock mechanism (20).
FRONT AXLE 4C-3
20.
21.
22.
23.
24.
25.
26.
27.
28.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
46.
47.
48.
49.
H u b Lock
R ing
R e ta in e r
N ut
R ing
N ut
O u te r B e aring
C up
H ub A n d D is c
C up
In n e r B earing
In n e r Seal
O u te r D e fle c to r
Seal
S p a ce r
Seal
B e aring
S p in d le
Brake B ra c k e t
Brake C a lip e r
S p la sh S h ie ld
H o u s in g
Tube
K n u c k le
A x le S h a ft
U -Jo in t
W a sh e r
N ut
F-01015
Figure 1 F ront A xle C om ponents
NOTICE: See N otice on page 4 C - 1 of this
section.
S u p p o rt the brake ca lip e r (40) so as not to stretch

or da m a g e th e brake hose.
4. S ho ck ab so rb e rs from the axle brackets.
9. Brake ca lip e r (40).
5. Front s ta b iliz e r bar.
Do not stretch or d a m ag e th e brake hose.
6. A xle vent tu b e and clip s (figu re 2).

7. Nuts, w ashers, U-bolts, spa cers and plates.
10. W hee l and tire.
S u p p o rt th e axle w ith a ja ck.
Lower the ve h icle and test.
8. A xle a sse m b ly out from un de r th e veh icle .
C lean
FRONT AXLE ASSEMBLY

REPLACEMENT
Axle assembly.
I?
++
R e m o ve o r D is c o n n e c t (F ig u re 1)
Raise the vehicle until the weight is removed from

the front springs. Support the vehicle with jack
stands placed behind the front springs.
In s p e c t
The assembly and repair or replace as necessary.
NOTICE: For steps 1, 5, 6 and 7, see N o tice
on page 4 C - 1 of this section.
1. Propeller shaft. Refer to Propeller Shaft (Sec. 4A).

2. Connecting rod from the steering arm. Refer to
FRONT SUSPENSION (SEC. 3C).
3. Brake caliper (40).
+4- In s ta ll o r C o n n e c t (F ig u re 1)
Axle assembly positioned under the vehicle.
1. Plates, spacers, U-bolts, washers and nuts.
4C-4 FRONT AXLE
0 Install or Connect
Lubricate the new bearings with a high melting point
type wheel bearing grease.
1. Bearing in a yoke ear.
2. Trunnion in the bearing.
3. Another bearing in the opposite yoke ear with the
trunnion aligned.
4. Bearing in each ear of the companion yoke.
Press the bearings in beyond the lock ring
grooves.
5. Lock ring at each bearing.
Tap the yoke lightly to seat the bearings against
the lock rings.
LOCKING HUB COMPONENT

REPLACEMENT
AUTOMATIC HUB COMPONENT REPLACEMENT
4- +
1. Screws (50) and O-ring seals (52).

2. Cover (52).
3. Seal (53).
4. Keeper (60).
5. Spring (54).
6. Inner race (55).
7. Bearing (56).
8. Retainer (58).
2.
3.
4.
5.
6.
7.
Axle vent tube and clips. Refer to figure 2.

Front stabilizer bar.
Shock absorbers to the axle brackets.
Brake caliper (40).
Connecting rod to the steering arm.
Propeller shaft.
Lower the vehicle.
AXLE JOINT COMPONENT

REPLACEMENT
Raise the vehicle.
1. Axle shaft. Refer to Axle Shaft Replacement earlier
in this section.
Support the shaft yoke in a bench vise or on a
short piece of pipe.
2. Trunnion
Using a brass drift and soft hammer drive on the
end of a trunnion bearing enough to drive the
opposite bearing from the yoke.
Support the other yoke and drive the trunnion
bearing out in the same manner.
Clean
The bearings and yokes.
Inspect
The bearings and yokes. Replace parts as
necessary.
9. Ring (57) using needle nose plier.

Pull the remaining components from the wheel.
10. Retaining ring (77) from the sleeve (67) groove.
Rotate the drag sleeve (75) until it drops into
engagement with the gear (59).
Lift and cock the drag sleeve (75) to unlock the
tangs of the brake band (74) from the window
of the inner cage (72), then move the drag sleeve
(75) and brake assembly away.
Im portant
NEVER REMOVE THE BRAKE BAND (74) FROM
THE DRAG SLEEVE (75). The spring tension of the
brake band (74) can be changed if the coils are over
expanded and the operation of the hub could be
affected.
11. Ring (73) from the groove in the clutch gear (59).
12. Inner cage (72).
While removing the inner cage (72) use a small
screw driver to pry the plastic outer cage (71)
away.
13. Outer cage (71).
Pry the plastic outer cage (71) tabs free from the
groove in the clutch gear (59) and move the outer
cage (71) away.
14. Sleeve (67) from the clutch gear (59).
Compress the return spring (64) and hold the
assembly in a compressed condition by using
the clamps shown in figure 4.
Position the assembly with the clamps in place in
a vice and hold both ends of the sleeve (67).
FRONT AXLE 4C-5
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
S crew
O -R ing Seal
C over
Seal
S p rin g
In n e r Race
B e aring
R ing
R e ta in e r
C lu tc h G ear
Keeper
R ing
62.
63.
64.
65.
66.
R e ta in e r Plate
R e ta in e r
R eturn S p rin g
R e ta in e r
G ear
67.
68.
69.
70.
71.
72.
73.
Sleeve
S to p R ing
S p rin g
Cam
O u te r Cage
In n e r Cage
R ing
74.
75.
76.
77.
79.
80.
81.
82.
Brake Band
Drag Sleeve
S p ace r
A d ju s tin g N ut
Lock R ing
N u t W ith Pin
R ing
A. S h ie ld
Figure 3Automatic Hub Components, V10/15, V20/25 and V30/35
F -03523
4C-6 FRONT AXLE
7.
8.
9.
61.
67.
70.
A.
Ring
Sleeve
Cam
C la m p
10.
B. Vs-inch
C. 11/4-inches
Im portant
D. 3/e-inch
Service the brake band (74) and drag sleeve (75)

as an assem bly and be sure the o riginal
lubricant has not been removed or contaminated.
Lubricant number 1052750 or its equivalent
m ust be used in this assembly.
Brake band (74) tangs.
Place the tangs of the brake band (74) on each
side of the lug of the outer cage (71) located in
the window of the steel inner cage (72). Cock
these parts to engage the tangs in this position.
Spacer (76) and retaining ring (77).
To the sleeve (67) above the drag sleeve (75).
Hub assembly to the vehicle.
Ring (57) to the clutch gear (59) unsplined end.
Locate the tangs of the ring (57) pointing away
from the vehicle.
Keeper (60).
Hold the tangs of the ring (57) together and
attach the keeper (60). For K10 and K20
assemble the O-ring seal (53) in the clutch gear
(59) groove and over the keeper (60).
Bearing (56) over the inner race (55).
Lubricate the bearing (56) with light wheel
bearing grease.
Steel balls should be visible when bearing (56) is
properly installed.
Retainer (58) into the outer race (55) hole.
Bearing (56) inner race (55) and retainer (58) into
the sleeve (67).
Spring (54) into the cover (52) bore.
Align cover (52) screw holes with the screw
thread holes in the clutch gear (59).
O-ring seals (51) and screws (50) in the cover (52).
The hub sleeve (67) and attached parts should
turn freely after assembly.
11.
F-01018
Figure 4Compressing the Return Spring

15. Ring (61).
While holding the sleeve (67) in the vise, remove
the clamps holding the return spring (64) and
then open the vise and release the return spring
(64).
16. Retainer plate (62).
17. Retainer (63).
18. Stop ring (68 ).
Align the ends of the stop ring (6 8 ) with the legs
of the cam (70) to allow removal.
19. Spring (69).
20. Cam (70) from the gear (66 ).
I*
12.
13.
14.
15.
16.
Inspect
++
Compress the return spring (64) and hold the

assembly together with clamps (figure 4).
Ring (61) in the groove of the sleeve (67).
Place the assembly (steps 1 through 7) into the
clutch gear (59) and support the clutch gear (59)
above a flat surface allowing the assembly to
drop down so that the tangs of the brake band
(74) may be assembled later.
Outer cage (71) into the clutch gear (59).
The ramps of the outer cage (71) must face the
cam (70).
Locate the outside tabs of the outer cage (71)
into the wide grooves of the clutch gear (59).
Inner cage (72) into the outer cage (71).
Align the tab of the outer cage (71) with the
window of the inner cage (72).
Ring (73).
Into the groove of the clutch gear (59) above the
outer cage (71).

Cam (70) over the flats of the gear (6 6 ).
Spring (69).
Compress the spring (69) and slide the large
diameter end against the gear (66 ).
Gear (66 ) over the splines of the sleeve (67).
Cam (70) should locate at the end of the sleeve
(67) having no splines.
17.
18.
19.
Im portant
The gear (6 6 ) and spring (69) should slide
freely over the splines of the sleeve (67).
Stop ring (6 8 ) to the groove of the sleeve (67).
Retainers (63 and 65) to each end of the spring (64).
Retainer (65) to the shoulder of the gear (66 ).
Retainer plate (62) to the retainer (63).
Tighten
Screws (50) to 5.1 N m (45 in. lbs.).
Im portant
The five cover screws (50) must be loosened
(three or four turns) and then pushed inward to
FRONT AXLE 4C-7
85. In te rn a l S nap R ing

86. H u b B ody
87. In n e r Drive G ear
88 . S p rin g
89. C lu tc h R ing
90. A x le S h a ft S nap R ing
91. S crew
92. H u b Cap
93. C o m p re s s io n S p rin g
94. C lu tc h C up
95. O -R ing Seal
96. D ial S crew
97. C lu tc h N ut
98. Seal
99. L ock R ing
Figure 5Manual Hub Components, V30/35
AUTOMATIC HUB TO THE WHEEL

ADJUSTMENT
Align the cut-outs on the drag sleeve (75) with the tabs
on the lock ring (80) as the splines of the clutch gear (59)
mesh with the splines of the wheel hub. Loosen the five
cover screws (50) three or four turns and push in on the
screws (50) to allow the ring (57) to expand into the groove
in the wheel hub. Torque the screws (50) to 5.1 N-m (45
inch lbs.).
A lock ring (80) is supplied with each new automatic

hub assembly. Assemble this lock ring (80) between the
nut with pin (81) and the adjusting nut (79) as follows:
MANUAL LOCKING HUB

REPLACEMENT
allow the retaining ring (57) to expand when

assembling the automatic locking hub to the
vehicle.
Use J-6893 to torque the nut with pin (81) to 6 8 N-m (50
ft. lbs.) to seat the wheel bearings; then back off the nut
with pin (81) and torque to 47 N-m (35 ft. lbs.) while
rotating the hub (figure 3).
Then back the nut with pin (81) off a maximum of 3/8
turn. Assemble the lock ring (80) over the axle shaft
against the nut with pin (81) so that the inner tang enters
the axle shaft keyway. One of the holes in the lock ring
(80) m ust engage the pin on nut (81). Thread the
adjusting nut (79) onto the axle shaft and tighten to 247
N-m (183 ft. lbs.).

1 . Screws (91).
2. Outer hub locking assembly (92, 93, 94, 95, 96, 97,
98, and 99).
3. Snap ring (90) from the axle shaft end.
4. Internal snap ring (85) from hub.
5. Body assem bly (8 6 , 87, 8 8 and 89).
L * Inspect
4C-8 FRONT AXLE

Spring (8 8 ).
Internal snap ring (85).
Inner drive gear (87) with thrust washers.
Plastic sleeve.
1.
2.
3.
4.
Body assembly (8 6 , 87, 88 and 89).

Internal snap ring (85) to the hub.
Snap ring (90) onto the axle shaft end.
Outer hub locking assembly (92, 93, 94, 95, 96, 97,
98 and 99).
5. Screws (91).
I9

+ 4-
MANUAL LOCKING HUB REBUILD

PROCEDURE
Lubricate inner body parts with ATF or a light

coat of wheel bearing grease.
Plastic sleeve.
Inner drive gear (87) with thrust washers.
Internal snap ring (85).
Spring (88 ).
Hub body (8 6 ).
Screws (91).
Outer hublock knob assembly should be replaced

only as a unit, because tim ing relationships are
difficult to restore if disassembly occurs. The inner
body m ay be d isa sse m b le d fo r c le a n in g and
component replacement.
Inspect

1. Screws (91).
2. Hub body (8 6 ).
SPECIFICATIONS
Nut-Splash Shield Retaining
IS X T 1
Cover Screw-Automatic Hub

Adjusting Nut-Axle Shaft
N-m
Ft. Lbs.
88
68
65
50
35
45 (inch lbs.)
183
47
5.1
247
SPECIAL TOOLS
5A-1
SECTION 5
BRAKES
CONTENTS
SUBJECT
PAGE
H yd ra u lic B ra k e s ............................................................................................................................................................................. 5A -1
H yd ra u lic Brake B o o ste r S y s te m s ........................................................................................................................................... 5A 1-1
H yd ra u lic F oundation B ra k e s .................................................................................................................................................... 5A 2-1
SECTION 5A
HYDRAULIC BRAKES
)C
manual as indicated at appropriate locations by the term inology NOTICE: See Notice on page 5A-1 of this section.
NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and
system, and/or could result in major repair expense. It must be replaced with one of the same part num ber or with
an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute
design. Torque values must be used as specified during reassembly to assure proper retention of this part.
CAUTION: W hen se rv ic in g w he el brake parts, do n o t crea te d u s t by g rin d in g o r sa nd in g brake lin in g s o r by
cle a n in g w heel brake p a rts w ith a d ry brush o r w ith co m p re ssed air. (A w a te r dam pened clo th s h o u ld be used).
M any w heel brake p arts co n ta in a sbe stos fib e rs w h ic h can becom e a irb o rn e if d u s t is crea ted d u rin g s e rv ic in g .
B re a th in g d u st co n ta in in g a sb e sto s fib e rs m ay cause se rio u s b o d ily harm .
CONTENTS
SUBJECT
PAGE
Brake System Diagnosis..............................................................................................................................................5A- 2

Road Testing the Brakes..........................................................................................................................................5A- 2
Diagnosis of Brake S y s te m ........................................................................................................................................ 5A- 2
On - Vehicle S ervice.................................................................................................................................................... 5A- 5
Bleeding the Brake Hydraulic S ystem ................................................................................................................... 5A- 5
Flushing the Brake Hydraulic S yste m ................................................................................................................... 5A- 6
Brake Pipes and Hoses............................................................................................................................................ 5A- 6
Combination Valve.................................................................................................................................................... 5A- 7
Height Sensing Brake Proportioning Valve........................................................................................................... 5A- 9
Brake Pedal A sse m b ly................................................................................................................................................ 5A-13
Checking Pedal Travel.............................................................................................................................................. 5A-13
Brake Pedal Replacement........................................................................................................................................5A-13
Brake Pedal Rod Replacement................................................................................................................................5A-15
Stoplamp S w itc h ...................................................................................................................................................... 5A-16
Parking Brake System.................................................................................................................................................. 5A-17
Parking Brake Pedal or Handle Replacement.......................................................................................................5A-17
Cable Replacem ent.................................................................................................................................................. 5A-18
Propeller Shaft Brake Replacement....................................................................................................................... 5A-22
Parking Brake A d ju stm e n t......................................................................................................................................5A-22
Master C ylinders.......................................................................................................................................................... 5A-24
D escription................................................................................................................................................................ 5A-24
Master Cylinder Replacement..................................................................................................................................5A-24
Bench B leeding........................................................................................................................................................ 5A-26
S pe cifica tio ns.............................................................................................................................................................. 5A-26
Special T o ols................................................................................................................................................................ 5A-28
5A -2 HYDRAULIC BRAKES
BRAKE SYSTEM DIAGNOSIS

ROAD TESTING THE BRAKES
EXTERNAL CONDITIONS THAT AFFECT

BRAKE PERFORMANCE
BRAKE TEST
The brakes should be tested on a dry, clean, reasonably
s m o o th and le ve l roa dw a y. A tru e te s t of b ra ke
perform ance cannot be made if the roadway is wet,
greasy or covered with loose dirt so that all the tires do
not grip the road equally. The testing will be adversely
affected if the roadway is crowned so as to throw the
weight of the vehicle toward the wheels on one side or if
the roadway is so rough that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both
light and heavy pressure; however, avoid locking the
wheels and sliding the tires on the roadway. Locked
wheels and sliding tires do not indicate brake efficiency
since heavily braked turning wheels will stop the vehicle
in less distance than locked wheels. More tire-to-road
friction is present with a heavily braked turning tire than
with a sliding tire.
1. TiresTires having unequal contact and grip on the

road will cause unequal braking. The tires must be
equally inflated and the tread pattern of the right
and left tires must be about equal.
2. Vehicle LoadingWhen the vehicle has unequal
loading, the most heavily loaded wheels require
more braking power than the others.
3. F ro n t W heel B e a rin g s L o o s e fr o n t w h e e l
bearings permit the disc to tilt and have spotty
contact with the linings causing erratic action.
4. Front End AlignmentM isalignm ent of the front
end, particularly in regard to limits on camber and
caster, will cause the brakes to pull to one side.
DIAGNOSIS OF BRAKE SYSTEM

PROBLEM
U neven Brake A ctio n
(Brakes Pull)
POSSIBLE CAUSE
1. Incorrect tire pressure.
2.
3.
4.
5.
6.
Front end out of alignment.

Loose suspension parts.
Worn out brake lining.
Incorrect lining material.
Malfunctioning caliper assembly.
7. Loose calipers.
8 . Contaminated brake linings.
9. M alfunctioning rear brakes.
10. Leaking wheel or piston cylinder seal.

11. Restricted brake tubes or hoses.
12. Unmatched tires on the same axle.
CORRECTION
1. Inflate evenly on both sides to specifictions.
2. Check and align to specifications.
3. Check all suspension mountings.
4. Replace with lining of correct material.
5. Replace with linings of correct material.
6 . Check for frozen or sluggish pistons
and the lubrication of the retainer bolts.
Caliper should slide.
7. Check and torque.
8 . Repair as necessary. Replace linings in
complete axle sets.
9. Check for inoperative self adjusters.
Weak return springs. Leaking wheel
cylinders.
10. Repair as necessary.
11. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
12 . Same style tires with about the same
tread should be used on the same axle.
HYDRAULIC BRAKES 5-3
DIAGNOSIS OF BRAKE SYSTEM (CONT.)

Brakes Squeak
1. Worn out linings.

2. Glazed brake lining.
3. Heat spotted rotors or drums.
4. Weak or incorrect brake shoe retention
springs.
5. Contaminated brake linings.
6. Incorrect lining material.
7. Brake assembly attachm ents missing or
loose.
8. Excessive brake lining dust.
Brake Pedal Pulsates
1. Excessive rotor lateral runout.

2. Rear drum s out of round.
3. Heat spotted rotors or drums.
4. Incorrect wheel bearing adjustments.
5. Out of balance wheel assembly attach
ments missing or loose.
6. Brake assembly attachments missing or
loose.
Excessive Pedal Effort
1.
2.
3.
4.
5.
Leaking vacuum system.

M alfunctioning power brake unit.
Worn out linings.
M alfunctioning proportioning valve.
Incorrect lining material.
6. Incorrect wheel cylinder.
Excessive Pedal
T ravel
CORRECTION
POSSIBLE CAUSE
PROBLEM
1. Insufficient fluid in master cylinder reser

voir.
2. Air in brake system.
3.
4.
5.
6.
M alfunctioning self adjusters.

Master cylinder.
Incorrect wheel bearing adjustment.
Im p ro p e rly a djusted m aster c y lin d e r
pushrod.
1'
1. Replace linings.
2. Replace linings.
3
3. Check per instructions. If within specifi
cations machine the rotor or drum.
4. Replace with new retention springs.
5. Repair as necessary. Replace linings in
complete axle sets.
6. Replace with linings of correct material.
i
1
8. Clean dust from brake assembly.
cations machine the rotor.
cations machine the drum.
cations machine the rotor or drum.
5. Repair as necesary.
1.
2.
3.
4.
5.
Repair as necessary.
Replace linings.
Replace with linings of correct m ateri
als.
6. Replace with corrrect size wheel cylin
der.
1. Fill reservoir with approved brake fluid.

Check for leaks and air in the system.
Check indicator light.
2. Check for leaks in lines, wheel cylin
ders, or master cylinder. Bleed the sys
tem.
4. Replace or repair as necessary.
6. Adjust master cylinder pushrod.
5-4 HYDRAULIC BRAKES
DIAGNOSIS OF BRAKE SYSTEM (CONT.)

PROBLEM
Brakes Drag
POSSIBLE CAUSE
1. M alfunctioning caliper assembly.
2. Contaminated or improper brake fluid.

3. Improperly adjusted parking brakes.
4. Restricted brake tube or hoses.
5. Malfunctioning proportioning valve.
.
11
9
Brake In d ica to r L ig h t
Com es On
1. Check for frozen or sluggish pistons

and the lubrication of the retainer bolts.
C aliper should slide.
4. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
6. M alfunctioning self adjusters.

7. M alfunctioning master cylinder.
8. Im pro pe rly a djusted m aster c y lin d e r
pushrod.
8. Adjust pushrod length.
1. Air in the brake system.
1. Check fluid level. Check for leaks in

lines, wheel cylinders, or master cylin
der. Bleed the system.
2. Check for faulty metering valve, or leak
ing. Repair as necessary.
4. Check parking brake. Repair as neces
sary.
5. Replace linings.
2. M alfunctioning master cylinder.

3. Contaminated or improper brake fluid.
4. Parking brake on or not fully released.
5.
6.
7.
8.
Worn out brake lining.

Incorrect wheel bearing adjustment.
Malfunctioning self adjusters.
Brake assembly attachments missing or
loose.
9. Im pro pe rly a djusted m aster cylin d e r
pushrod.
Excessive Brake Pedal

Effort
CORRECTION
1. Loose or broken power steering pump

belt.
2. No fluid in the power steering reservoir.
3. Leaks at Hydro-Boost tube fittings.
4. External leakage at the accumulator.
5. Faulty booster piston seal causing leak
age at the booster flange vent.
6. Faulty booster input rod seal with leakagae at the input rod end.
7. Fautly booster cover seal with leakage
between the housing and cover.
8. Fautly booster spool plug seal.
9. Adjust pushrod length.
1. Tighten or replace the belt.

2. Fill reservoir and check for external
leaks.
3. Tighten fittings or replace tube seats, if
faulty.
4. Replace seal and retainer
5. Overhaul with new seal or input rod
and piston assembly.
6. Overhaul with new seal kit.
8. Overhaul with spool plug seal kit.
HYDRAULIC BRAKES 5A-5
ON VEHICLE SERVICE
BLEEDING THE BRAKE
HYDRAULIC SYSTEM
A bleeding operation is necessary if air has been
introduced into the hydraulic brake system.
It may be necessary to bleed the system at all four
wheels if air has been introduced by a low fluid level
condition in the master cylinder or if the brake pipes have
been disconnected at either the master cylinder or the
com bination valve. If a pipe is disconnected at one wheel,
then only bleed that particular wheel.
The tim e required to bleed the hydraulic system when
the master cylinder is removed can be reduced if the
master cylinder is filled with fluid and as much air as
possible is bled from the cylinder before installing it on
the vehicle.
MANUAL BLEEDING
If the vehicle is equipped with power brakes, deplete
the vacuum reserve by applying the brakes several tim es
with the engine off.
Use extreme care to prevent brake fluid from contacting
any painted surface.
1. Fill the master cylinder reservoirs with brake fluid
specified in MAINTENANCE AND LUBRICATION
(Sec. OB).
Maintain the fluid level in the reservoir during
the bleeding operation.
2. If the master cylinder is suspected to have air in the
bore, it must be bled before any wheel cylinder or
caliper.
Remove the forward brake pipe connection at
the master cylinder.
Allow brake fluid to flow from the connector
port.
Connect the brake pipe but do not tighten.
3. Slowly depress the brake pedal allowing the air to
bleed from the loose fitting.
Tighten the fitting before releasing the pedal.
Wait 15 seconds, and repeat this sequence,
including the 15 second wait until all the air is
purged from the bore.
4. After all the air has been removed from the forward
connection disconnect the rear pipe.
Allow brake fluid to flow from the connector
port.
Connect the brake pipe but do not tighten.
5. Slowly depress the brake pedal allowing the air to
bleed from the loose fitting.
Tighten the fitting before releasing the pedal.
Wait 15 seconds, and repeat this sequence,
purged from the bore.
6. If it is known that the calipers and wheel cylinders
do not contain any air, then it will not be necessary
to continue. Otherwise bleed each wheel in the
following sequence.
Right rear
Left rear
Right front
Left front
7. Attach a hose to the wheel cylinder/caliper bleeder
screw.
Immerse the opposite end of the hose into a
container partially filled with clean brake fluid.
8. Slowly depress the brake pedal one tim e and hold.
Loosen the bleeder screw to purge the air from
the wheel cylinder/caliper.
Tighten the bleeder screw and slowly release
the pedal.
Wait 15 seconds, then repeat this sequence,
purged from the wheel cylinder/caliper.
9. Continue steps 7 and 8 at each wheel until the
entire brake system has been bled.
10. Check the brake pedal for sponginess and the
bra ke w a rn in g la m p fo r an in d ic a tio n o f an
unbalanced pressure. Repeat the entire bleeding
procedure to correct either of these two conditions.
PRESSURE BLEEDING
The pressure bleeding equipm ent m ust be of the
d ia ph rag m type. It m ust have a rub be r d ia p h ra g m
between the air supply and the brake fluid to prevent air,
moisture, oil, and other contaminants from entering the
hydraulic system. Also adapters are needed, depending
on the type of master cylinder used.
Tools Required:
J -2 9 5 6 7 B rake B le e d e r A d a p te r (P la s tic
Reservoir)
J-23518-01 Brake Bleeder Adapter (Cast Iron
Reservoir)
J-23709 Com bination Valve Depressor
NOTICE: It is very important that the correct
m aster cylinder bleed er adapter be used to
avoid possible damage to the master cylinder
reservoir.
1. Fill the pressure tank at least 1/3 full of brake fluid.
The bleeder must be re-bled each tim e fluid is
added.
Charge the bleeder to 140 - 170 kPa (20 to 25
psi).
2. Use J-23709 to depress and hold the valve stem on
the combination valve during the bleeding operation
(figure 1).
Install the correct bleeder adapter (figures 2
and 3).
3. Bleed each wheel in the following sequence.
Right rear
Left rear
Right front
Left front
4. Connect the hose from the bleeder to the adapter at
the master cylinder.
Open the tank valve.
5. Attach a hose to a brake bleeder screw.
5A-6 HYDRAULIC BRAKES
B-07785
Figure 1Installing Combination Valve Depresser

6. Open the bleeder screw at least 3/4 of a turn and
allow the fluid to flow until no air is seen in the fluid.
Close the bleeder screw.
7. Repeat step six at all the wheels.
8. Check the brake pedal for sponginess , repeat the
entire bleeding procedure if this condition is found.
9. Remove J-23709.
Disconnect the line from the bleeder adapter.
Remove bleeder adapter.
10. Fill the master cylinder to the proper level with brake
fluid.
______________________________________________ B-07783
Figure 3 Cast Iron Reservoir Bleeder Adapter
FLUSHING THE BRAKE

HYDRAULIC SYSTEM
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system.
Flushing is also recommended if there is any doubt as
to the grade of fluid in the system or if fluid has been used
which contains the slightest trace of mineral oil. Flush the
system whenever there is any question of contamination.
Flushing is performed at each bleeder valve in the
same manner as the bleeding operation, except that the
bleeder valve is opened 1 1/2 turns and the fluid is forced
through the lines and bleeder valves until it emerges clear
in color. Refer to Bleeding the Brake Hydraulic System ,
in this section.
Check master cylinder fluid level after flushing at each
valve and re p le n is h if re q u ire d . W hen flu s h in g is
completed at all bleeder valves, make certain the master
cylinder reservoir is filled to proper level.
BRAKE PIPES AND HOSES

T h e h y d r a u lic b ra k e s y s te m c o m p o n e n ts are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, and the frame and rear differential. When the
hydraulic pipes have been disconnected for any reason,
the brake system must be bled after reconnecting the
pipe, refer to Bleeding the Brake Hydraulic System in
this section.

FLEXIBLE HOSE
On the front brakes the hose is connected to the caliper
with a bolt and copper washers. The fitting at the other
end of the hose is secured at the frame with either a nut
or a clip.
At the rear differential one end of the hose is connected
to the differential with a bolt. The other end is secured at
the frame with either a nut or a clip.
Flexible Hose Inspection

The flexible hoses should be inspected for any signs of
road damage which will cause cracks and chafing of the
other cover. If any of these conditions are visible, replace
the hose.
Hose Replacement
Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
1. Steel pipe.
2. Clip or nut (31).
3. Bolt (34).
4. Washers (33).
5. Hose (32).
Use new copper washers when installing the hose.

1. Hose (32).
The hose must not be twisted.
Important
2.
3.
4.
5.
The hose installation must not contact any

suspension components.
Washers (33).
Bolt (34).
Clip or nut (31).
Steel pipe.
Bleed the brakes, refer to Bleeding the Brake
Hydraulic System in this section.
BRAKE PIPES
When replacing a steel brake pipe, always use steel
piping which is designed to withstand high pressure and
resist corrosion. The same size pipe must be used as the
one removed.
NOTICE: Never use copper tubing for hydraulic
brake lines because copper is subject to fatique
cracking, and corrosion which could result in
brake failure.
Brake pipes that run parallel to each other must

maintain a 6 mm (1/4-inch) clearance.
Pipe Flaring (Figure 5)

Tools Required:
J-23530 Flaring Tool.
J-23533-B Tube Cutter.
In order to ensure a proper flare, a special flaring tool
must be used. When using the tool, instruction furnished
by the tool manufacturer should be followed. Always
inspect newly formed flares for cracks or malformations
which m ight cause leaks. After flaring, blow out the brake
pipe with compressed air before installing on the vehicle.
NOTICE: Double lap flaring tool must be used,

as single flaring tools cannot produce a flare
strong enough to hold the necessary pressure.
1. Use steel pipe and fittings of the correct size. The
outside diameter of the pipe is used to specify the
size.
2. Cut the pipe to length. Add 3 mm (Vs-inch) to the
length for each flare.
3. Flare the pipe ends by following the instructions with
the tool.
4. Bend the pipe to match the old pipe by using a pipe
bender.
COMBINATION VALVE
The combination valve is comprised of three sections,
each serving a different function (figure 6).
The metering or hold off section of the valve limits the
pressure to the front disc brakes until a predetermined
front input pressure is reached, enough to overcome the
rear shoe retractor springs. There is no restriction to the
inlet pressures below 20 kPa (3 psi) to allow for pressure
equalization during the no apply periods.
The proportioning section of the com bination valve
proportions outlet pressure to the rear brakes after a
predetermined rear input pressure has been reached.
This is done to prevent rear wheel lock-up on the vehicles
with light rear wheel loads.
The valve is designed to have a By-Pass feature which
assures full system pressure to the rear brakes in the
event of a front brake system malfunction, also full front
pressure is retained in the event of rear m alfunction.
The pressure differential warning switch is designed to
constantly compare front and rear brake pressure from
the master cylinder and energize the warning lamp on the
dash in the event of a front or rear system malfunction.
The valve and switch are so designed that the switch will
latch in the w arning position once a malfunction has
occured. The only way the lamp can be turned off is to
repair the m alfunction and apply a pedal force required to
develop about 3102 kPa (450 psi) line pressure.
ELECTRICAL CIRCUIT TEST

1. Disconnect the wire from the switch on the valve.
Connect a jum per wire from the switch wire to
ground.
2. Turn the ignition key to O N .
The warning lamp should light.
If the lamp will not light check the bulb. If the
bulb is good, refer to Chasis Electrical (Sec.
8B) for further diagnosis.
3. Turn the ignition off.
Disconnect jum per wire and connect the wire
to the switch terminal.
Valve Warning Switch Test

Support with suitable safety stands.
2. Attach a hose to a rear brake bleeder screw.
Make sure the master cylinder reservoir is full.
5A -8 HYDRAULIC BRAKES
31.
32.
33.
34.
N ut or C lip
F le x H ose
W asher
B o lt
B-07786
Figure 4Flexible Hoses

8. Turn the ignition key off.
If the warning lamp does not light during steps
3 and 6 but does light when a jum per is
connected to ground, the w arning sw itch
p o rtio n o f th e v a lv e is fa u lty . Do n o t
disassem ble any portion of the valve. It must
be replaced.
9. Remove the safety stands.
Lower the vehicle.
C heck and fill the m aster c y lin d e r to the
proper level.
VALVE REPLACEMENT
3. Turn the ignition key to O N .

Open the bleeder screw while a helper applies
moderate pressure to the brake pedal.
Close the bleeder screw before the helper
releases the brake pedal.
4. Reapply the brake pedal with moderate to heavy
pressure.
The lamp should go out.
5. Attach a hose to a front brake bleeder screw.
Make sure the master cylinder reservoir is full.
6. Open the bleeder screw while a helper applies
moderate pressure to the brake pedal.
Close the bleeder screw before the helper
releases the brake pedal.
7. Reapply the brake pedal with moderate to heavy
pressure.
The lamp should go out.
The combination valve is not repairable and must be

replaced as a complete assembly.
Care must be taken to prevent brake fluid from
contacting any painted surface.
1. Hydraulic pipes.
Plug the pipes to prevent the loss of fluid or
the entrance of dirt.
2. Warning switch harness.
3. Bolts.
4. Com bination valve.

1.
2.
3.
4.
Position valve on the bracket.

Bolts.
Warning switch harness.
Hydraulic pipes.
Bleed the brake system. Refer to Bleeding Brake
HEIGHT SENSING BRAKE

PROPORTIONING VALVE
The height sensing brake proportioning valve is used
on series 30 models (figure 8). This will provide optimum
brake balance and efficiency. The vehicle braking force is
distributed to the front and rear wheels as determ ined by
either a light or heavy payload condition.
Figure 6Combination Valve
A.
B.
C.
D.
G-Van
R-V Truck
P M o d e l (42)
P M o d e l (32)
B-09427
Figure 7Combination Valves
The vaive is mounted on the frame, and a linkage

connects the valve to a bracket that is mounted on the
axle.
CAUTION: Adding any suspension accessories

or other equipment (such as load leveling kits,
air shocks, suspension lift kits, additional
spring leafs, etc.), or making modification that
will change the distance between the axle and
the frame w ithout changing the load, w ill
p ro v id e a fa lse re a d in g to the brake
p ro p o rtio n in g valve. T his could re su lt in
unsatisfactory brake performance which in turn
could result in an accident and possibly
personal injury.
VALVE REPLACEMENT
Raise the vehicle.
Support the frame with suitable safety stands. The
axle must be allowed to hang free.
Clean the exterior of the valve to prevent dirt from

contam inating the hydraulic system.
1. Brake pipes (51).
2. Nut from the shaft (48).
3. Lever (49).
4. Bolts (46) and washers (47).
5. Valve (50).

1. Position the valve on the mounting bracket.
2. Washer (47) and bolts (46).
3. Lever (49).
Refer to Proportioning Valve A djustm ent in
this section.
4. Nut (48). Torque to 10 N-m (89 in. lbs.).
5. Brake pipes (51).
B le ed b ra ke s. R e fe r to B le e d in g th e B rake
Hydraulic System , in this section.
Remove the safety stands.
Lower the vehicle.
Test the brakes.
PROPORTIONING VALVE ADJUSTMENT

If a front wheel lockup is experienced when the vehicle
is being operated near the maximum GVWR with a lower
than desired brake application, the valve adjustm ent
should be checked. Use the following procedure to check
the adjustment.
Support the frame with suitable safety stands.
The axle must be allowed to hang free.
2. Remove the nut from the valve shaft.
Remove the lever.
3. Select the appropriate adjustment gage from the
chart.
5. Install the nut on the shaft. Torque to 10 N m (89 in.

lbs.)
6. Sever the tang on the adjustm ent gage (figure 11).
7. Remove the safety stands.
Lower the vehicle.
Test the brakes.
A. A d ju s tm e n t G age
B-07794
Figure 10Installing Adjustment Gage

ADJUSTMENT GAGE CHART
Part
Number
CodeColor
14061394
Green
14061395
Black
14061396
Blue
15592484
Red
15548904
Yellow
RPO
RPO
RPO
RPO
RPO
Vehicle Combination
R/V 3500 with G52
R20903
R3500 Less G52
R/V20903
G30005/06 with LB4/L05
V3500 Less G52
G31305/06 with LL4/LT9
R/V20903 with VD1
V20906 with VD1
V20906
G52: Extra Capacity Rear Spring

LB4: 4.3 Liter
L05: 5.7 Liter _
LL4: 6.2 Liter
LT9: 5.7 Liter H.D.
4. Rotate the valve shaft to permit the installation of

the adjustment gage (figure 10).
The center hole of the adjustment gage must
seat on the D shape of the valve shaft.
The g a g e ta n g
mounting hole.
m u st se a t in th e va lv e
NOTICE: Do not drive the lever assembly onto

the valve shaft by using nut or proper valve
setting may be disturbed.
BRAKE PEDAL ASSEMBLY
1.
2.
3.
4.
6.
7.
11.
12.
A.
B.
B o lt
N ut
B u s h in g s
S p a ce r
R e ta in e r
W a sh er
C lu tc h Pedal
Brake Pedal
M anual T ra n sm issio n
B-09428
Figure 12R-V Brake Pedal Components
CHECKING PEDAL TRAVEL
8. Clutch Pedal (11) (if equipped).

9. Bushings (3).
At frequent intervals the brake pedal should be checked

for travel. Travel is the distance the pedal moves toward
the floor from a full released position. This check should
be made with the brakes cold and about 122 N (90 lbs.) of
force on the pedal. On vehicles with power brakes the
pedal must be pumped at least three times with the
e n g in e o ff b e fo re m a k in g th e c h e c k . F o llo w th e
specifications below for the correct travel.
R-V-G M a n u a l........................................115 mm (4.5-inches)
R-V-G P o w e r............................................ 90 mm (3.5-inches)
P (Except J F 9 ) ........................................90 mm (3.5-inches)
P (JF9).....................................................150 mm (6.0-inches)
BRAKE PEDAL REPLACEMENT
10. Spacer (4).

1. Spacer (4).
2. Bushings (3).
3. Brake pedal (12).
4. Clutch pedal (11) (if equipped).
section.
5. Bolt (1) and nut (2).
Tighten
R-V AND P-30 (32) MODELS
1.
2.
3.
4.
5.
6.
Retainer (6).
Washer (7).
Pin (10) and washer (9).
Pushrod (8).
Return spring (5).
Nut (2) and bolt (1).
Nut to 63 N m (46 ft. lbs.) for P30 (32) Models.

Nut to 34 N m (25 ft. lbs.) for R-V Models.
6. Return spring (5).
7. Washer (9) and pin (10).
8. Pushrod (8).
9. Washer (7) and retainer (6).
Check the stoplamp switch adjustment. Refer to
Stoplamp Sw itch.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12.
B o lt
N ut
B u s h in g s
S p a ce r
R eturn S p rin g
R e ta in e r
W a sh ers
P u shro d
W a sh e r
Pin
Brake Pedal
B-07771
Figure 13P30(32) Brake Pedal Components

G-Model
4- +
1.
2.
3.
4.
5.
6.
Retainer (6).
Washer (9).
Pushrod (8).
Washer (7).
Return spring (5).
Retainer (14) or clutch attaching components (15) (if
equipped).
7. Pin (13) or clutch pedal (11) (if equipped).
9. Bushings (3).

1.
2.
3.
4.
B ushings (3).
Brake pedal (12).
Pin (13) or clutch pedal (11) (if equipped).
R etainer (14) or clutch attaching com ponents (15)
(if equipped).
5. R eturn sp ring (5).
6. W asher (7).
7.
8.
9.
Pushrod (8).
W asher (9).
R etainer (6).
C heck the stoplam p sw itch a djustm e nt. Refer to
S toplam p S w itc h .
P 30 (42) MODEL
4- +
1.
2.
3.
4.
5.
6.
7.
8.
9.

Retainer and washer.
Pushrod and washer.
Clutch attaching components (15) (if equipped).
Clutch pedal (11) (if equipped).
Return spring (5) (if equipped).
Nut (16) and bolt (18).
Shaft (17).
Brake pedal (12).
Bushings (3).

Lubricate the pivot points with Delco Brake Lube or
equivalent.

3. B u s h in g
B-07770
Figure 14G-Van Brake Pedal Components

1.
2.
3.
4.
5.
6.
7.
8.
9.
Bushings (3).
Brake pedal (12).
Shaft (17).
Bolt (18) and nut (16).
Clutch pedal (11) (if equipped).
Return spring (5) (if equipped).
Clutch attaching components (15).
Washer and pushrod.
Washer and retainer.
Check the stoplamp switch adjustment, refer to
Stoplamp Sw itch.
BRAKE PEDAL
ROD REPLACEMENT
P 30 (32) MODEL
1. Retainer (6).
2. Nut (16).
3. Bolt (17) and washers (7 and 9).
4. Screws (18).
5. Raise the vehicle and support it with suitable safety
stands.
6. Retainer (23).
7. Nut (22).
9. Brake rod (8).
10. Boot (24).

page 54-7 of this section.
1. Boot (24).
f t
Adjust
Brake rod to 790 mm (31.00-inches) from the

centers of the bolt holes.
2. Brake rod (8).
4. Nut (22) and retainer (23).
18. Bolt
B-07772
Figure 15 P30(42) Brake Pedal C om po n en ts
Tighten
Lower the vehicle.
5. Screws (18).
7. Nut (16) and retainer (6).
Tighten
STOPLAMP SWITCH
The design of the switch m ounting provides for an
automatic adjustment when the brake pedal is returned to
its stop. There are two styles of switches, the determining
factor is if the vehicle is equipped with cruise control. For
electrical d iagnosis of the stoplam p sw itch refer to
CHASSIS ELECTRICAL (SEC. 8B).
SWITCH REPLACEMENT
|<"| Remove or Disconnect
1. Remove the negative battery cable.
3. Switch.
Install or Connect
1. Switch.
Adjust
Refer to Switch A djustm ent.
3. Negative battery cable.
SWITCH ADJUSTM ENT
1. Depress the brake pedal and press the switch in
until it is firm ly seated in the clip.
Audible clicks can be heard as the threaded
portion of the switch is pushed through the
clip.
2. Pull the brake pedal against the pedal stop until the
audible click can no longer be heard.
3. Electrical contact should be made when the brake
pedal is depressed the specified distance.
R-V models 25-31 mm (1.0-1.24 inches).
G-P models 11-24 mm (0.45-0.95 inches).
6.
7.
8.
9.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Retainer
W asher
Brake Rod
W asher
Nut
B olt
Screw
B olt
W asher
W asher
N ut
R etainer
Boot
B-07775
Figure 16P30(32) Brake Pedal Rod Components
PARKING BRAKE SYSTEM

PARKING BRAKE PEDAL OR
HANDLE REPLACEMENT

section for steps 2 and 4.
R-V-G MODELS
4* +
The parking brake must be in the released position.

1. Nuts (1).
2. Release rod (3).
3. Bolt (2).
4. Brake assembly.
5. Parking brake cable.
1. Parking brake cable.

2. Bolt.
Tighten
Refer to Torque Specifictions in this section.

3. Release rod (3).
4. Nuts (1).
Tighten
R efer to Torque S p e c ific a tio n s in th is
section.
5. C heck the p a rkin g brake a d ju stm e n t, refer to
Parking Brake A djustm ent in this section.

7. Spacer (14).
section.
8. Washer (13) and bolts (12).
9. Washers (11) and nuts (10).
Tighten
Nuts to 24 N m (18 ft. lbs.)

C heck the p arkin g brake a djustm e nt, refer to
Parking Brake A djustm ent in this section.
CABLE REPLACEMENT
FRONT CABLE REPLACEMENT
(R-V MODELS)
|++| Remove or Disconnect (Figures 19 and 20)
stands.
1. Nut (31) from the equalizer (32).
2. Connector (33) from the front cable.
3. Bend retaining fingers (34) and (35).
4. Cable from the brake pedal assembly.
5. Cable assembly (36).
Attach a piece of wire to the cable to help in
installation.
0
1. N uts
2. B olt
3. Release Rod
B-09421

M ake su re all th e re ta in in g fin g e rs are
completely through the holes.
2. Cable to the pedal assembly.
3. Connector (33).
4. Nut (31) onto the equalizer (32).
Adjust
Figure 17Removing Parking Brake Pedal on
R-V and G Models
P MODELS
++
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

The parking brake must be in the released position.
Spacers (14).
Cotter pin (15) and washer (16).
Clevis pin (17).
Bolt (20).
Spacer (21).
Cable (22).
Handle assembly.

1.
2.
3.
4.
5.
Cable (22).
Clevis pin (17).
Washer (16) and cotter pin (15).
Spacer (21).
Bolt (20).
Refer to Parking Brake A djustm ent in this

section.
Lower the vehicle.
FRONT CABLE REPLACMENT

(G AND P MODELS)
stands.
2. Connector (33) from the front cable.
3. Bolts (37) and clips (38).
4. Cable from the pedal/handle assembly.
Bend the retaining fingers (34).
Attach a piece of wire to the cable to help in
installation.

M ake sure all th e re ta in in g fin g e rs are
completely through the holes.
2. Cable to the pedal/handle assembly.
Figure 18Removing Parking Brake Lever on P Models
31. N u t
32. E q u a lize r
B-07777
Figure 19Equalizer Components

34. Fram e R e ta in in g F in g e rs
35. Pedal R etaining Fingers
36. C ab le A s s e m b ly
B-07778
Figure 20R-V Front Cable Components
Figure 21P Model Front Cable Components

3. Clips (38) and bolts (37).
4. Connector (33).
ft
Adjust
P arking brake. R efer to P arking
Adjustm ent , in this section.
Brake
Lower the vehicle.
CENTER CABLE REPLACEMENT

stands.
2. Both front and rear connectors (33).
3. Cable.

36.
37.
38.
1. Cable.
C able A ssem bly

B olt
C lip
2. Connector (33).
B-07781
Figure 22G Model Front Cable Components
Adjust
P arking brake. R efer to P a rkin g Brake
Lower the vehicle.

REAR CABLE REPLACEMENT
stands.
2. Connector (33).
3. B ra ke d ru m a nd s h o e a s s e m b ly . R e fe r to
HYDRAULIC FOUNDATION BRAKES (SEC. 5A2).
Bend in retaining fingers at the backing plate.
4. Retaining clip at the frame support.
5. Cable assembly.

1. Cable assembly.
M ake su re a ll th e re ta in in g fin g e rs are
completely through the backing plate.
2. Retaining clip at the fram e support.
3. B ra k e s h o e s a nd d ru m a s s e m b ly . R e fe r to
HYDRAULIC FOUNDATION BRAKES (SEC. 5A2).
4. Connector (33).
Adjust
P a rkin g brake. R efer to P arking Brake
Adjustm ent in this section.
Lower the vehicle.
PROPELLER SHAFT
BRAKE REPLACEMENT

L u b rica te the shoe pads and a d ju s tin g screw
threads with a thin coat of white lithium grease.
1. Adjusting screw (60) and adjusting screw spring (58)
to both shoes (68).
2. Shoe assembly (68).
3. Lever retaining ring (67).
4. Lever strut (55) and strut spring (57).
5. Washers (63).
6. Hold down springs (64).
7. Hold down clips (65).
8. Return spring guide (72).
9. Return springs (56 and 57)
10. Drum (66).
11. Propeller shaft, refer to PROPELLER SHAFT (Sec.
4A) in this manual.
A djust
P arking brake. R efer to P arking Brake
Lower the vehicle.
PARKING BRAKE ADJUSTMENT

The parking brakes must be adjusted whenever the
p a rk in g b ra k e c a b le s h ave b e e n re p la c e d o r
disconnected. Also if the brake holding ability is not
adequate. Before adjusting the parking brakes check the
condition of the service brakes. The service brakes must
be adjusted properly before proceeding with the parking
brake adjustment.
CABLE INSPECTION
stands.
1. Propeller shaft, refer to Propeller Shaft (Sec. 4A).
CAUTION: See Caution on page 5A-1 of this

section.
2. Drum (66).
It may be necessary to back off the adjusting
screw.
3. Return springs (56 and 71).
4. Return spring guide (72).
5. Hold down clips (65).
6. Hold down springs (64).
7. Washers (63).
8. Lever strut (55).
9. Strut spring (57).
10. Lever retaining ring (67).
11. Shoes (68).
12. Adjusting screw (60).
13. Adjusting screw spring (58).
Inspect
All parts for discoloration due to heat, or stress.
Brake drum for scoring and heat spots. Machine
drum if needed.
Check the parking brake system for free operation. The

brake lever must return to the released position without
sticking or binding. If a problem is present check the
cable routings for kinks or binding. Clean and lubricate
the parking brake assembly and cables with Delco brake
lube or equivalent.
FOOT PEDAL TYPE

1. Block the front wheels.
Raise and support the rear axle with suitable
safety stands.
2. Loosen the equalizer nut.
3. Set the parking brake pedal to four clicks.
A djust
Equalizer nut until the wheels rotate forward
with a moderate drag.
4. Release the parking brake and rotate the rear
wheels. There should be no brake drag.
5. Remove the safety stands and lower the vehicle.
6. Unblock the front wheels.
LEVER TYPE
safety stands.
2. Turn the adjusting knob on the parking brake lever
counterclockwise until it stops.
Apply parking brake.
3. Loosen the equalizer nut.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Support Plate
W asher
A n ch o r Pin Nut
Hold Down Pin
Lever S trut
Return Spring
S trut Spring
A d ju stin g Screw Spring
Adjusting Screw Socket
A d ju s tin g Screw
A d ju s tin g Screw Nut
Cable
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
W asher
Hold Down Spring
Hold Down C lip
Drum
Lever R etaining Ring
Shoe
W asher
O perating Lever
Return Spring
Return Spring G uide
A nchor Pin
B-07779
Figure 23Propeller Shaft Brake Components
ft
Adjust
Equalizer nut until a light drag is felt while

rotating the wheels forward.
Knob on the parking brake lever until a definite
snap over center is felt.
Release the parking brake and rotate the rear
wheels. There should be no brake drag.
Remove the safety stands and lower the vehicle.
Unblock the front wheels.
INTERNAL EXPANDING (PROPELLER SHAFT)

CAUTION: See Caution on page 5A-1 of this
section.
safety stands.
2. Remove the clevis pin connecting the pull rod and
relay lever.
3. Rotate the brake drum to align the access hole with
the adjusting screw.
Manual transmissions - the adjusting screw
is located at the bottom of the shoe.
Automatic transmission - the adjusting screw
is located at the top of the shoe.
When adjusting the parking brake for the first

time, it will be necessary to remove the lanced
area from the drum . The drum m ust be
removed to clean out all the metal shavings.
Refer to PROPELLER SHAFTS (Sec. 4A).
Adjust
Adjusting screw until the drum cannot be
rotated by hand.
Back off the adjusting screw ten notches. The
drum should rotate freely.
Place parking brake lever in the full release position.
Take up the slack in the cable to overcome the
spring tension.
ft
A djust
The clevis of the pull rod to align with the hole

in the relay lever.
Install the clevis pin.
Install new cover in the drum access hold.
Remove the safety stands and lower the vehicle.
Unblock the front wheels.
MASTER CYLINDERS
Figure 25Composite Master Cylinder
DESCRIPTION
There are two designs of master cylinders available
depending on the brake option.
O ne is a fu ll c a s t iro n d e s ig n in c o rp o ra tin g a
conventional front to rear brake split (figure 24). The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.
The second style master cylinder is designed for use
with a system using the low drag calipers (figure 25). In
addition to the standard master cylinder functions, a quick
take-up feature is included. This provides a large volume
of fluid to the wheels at low pressure with the initial brake
application. This large volum e of fluid is needed to

overcome the clearance created by the seal retracting the
pistons into the front calipers and the spring retraction of
the rear drum brake shoes.
MASTER CYLINDER
REPLACEMENT
Apply the vehicles parking brakes.
1. Brake pipes.
Cover the ends of the pipes to prevent dirt
from entering the system.
2. M ounting nuts.
3. Master cylinder.
Figure 26Master Cylinder Installations
If the vehicle is equipped with manual brakes,

refer to Brake Pedal Replacem ent for the
removal of the pushrod from the pedal.
BENCH BLEEDING
l Install or Connect (Figure 26)

Prior to installation, refer to Bench Bleeding in
this section.
1. Master cylinder.
If the vehicle is equipped with manual brakes,
refer to Brake Pedal R eplacem ent for the
installation of the pushrod to the pedal.
NOTICE: See Notice"

section.
on
page 5A-1 of this
2. Mounting nuts.
Tighten
Nuts to 27 N m (20 ft. lbs.), G and P models.

Brake pipes.
Bleed the brakes, refer to Bleeding the Brake
Hydraulic System in this section.
Release the parking brakes.
The purpose of bench bleeding is to remove the air

from the master cylinder so when it is installed on the
vehicle, the brake system bleeding will be reduced.
1. Plug the outlet ports and m ount the master cylinder
in a vise with the front end tilted slightly down.
2. Fill the reservoir with clean brake fluid.
Using a tool with a smooth rounded end tool,
stroke the prim ary piston about 25 mm (1-inch)
several times.
As air is bled from the master cylinder, with the
outlets plugged, the
resistance to the prim ary
piston travel will not allow the full 25 mm (1-inch)
stroke.
3. Reposition the master cylinder in the vise with the
front end of the master cylinder tilted slightly up.
Again stroke the prim ary piston about 25 mm
(1-inch) several times.
4. Reposition the master cylinder in the vise to the
level position. Loosen the plugs one at a time and
push the piston into the bore to force the air from the
cylinder. To prevent air from being sucked back into
the cylinder, tighten the plug(s) before allowing the
piston to return to its original position.
5. Fill the reservoir.
Normal bleeding procedures should be followed
after the master cylinder is installed.
SPECIFICATIONS
BRAKE SYSTEMS
SYSTEM
FRONT BRAKES
REAR BRAKES
BRAKE ASSIST
GASOLINE ENGINE VEHICLES

R-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.04

Disc 11.86 x 1.04
Drum 11.0 x 2.00

Drum 11.0 x 2.00
None (Manual Brakes)

Vacuum Single Diaphragm
Drum 11.00 x 2.00

Drum 11.00 x 2.00

Drum 11.15 x 2.75

Drum 11.15 x 2.75
Drum 13.00 x 2.50
Drum 13.00 x 3.50
Disc 13.75 x 1.54
Vacuum Dual Diaphragm

Vacuum Dual Diaghragm
Hydraulic Hydro-Boost
G-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.29

Disc 11.86 x 1.29
ALL MODELS
JB5
JB6
JB7
JB8
JF9
Low Drag
Low Drag
Conventional
Conventional
Conventional
Disc
Disc
Disc
Disc
Disc
11.86 x 1.29
12.50 x 1.28
12.50 x 1.28
12.50 x 1.54
14.25 x.1.54
DIESEL ENGINE VEHICLES

JD3
JD5
JD6
JD7
Low Drag
Low Drag
Conventional
Conventional
Disc 11.86 x 1.29

Disc 11.86 x 1.29
Disc. 12.50 x 1.28
Disc 12.50 x 1.28
Drum
Drum
Drum
Drum
11.00 x
11.15 x
11.15 x
13.00 x
2.00
2.75
2.75
2.50
Hydraulic-Hydro-Boost
BRAKES 5A-27
R
Master Cylinderto Dash or Booster
27 N m (20 ft. lbs.)
27 N-m (20 ft. lbs.)
27 N-m (20 ft. lbs.)
27 N-m (20 ft. lbs.)
Combination Valve Mounting Bolts
17 N m (150 in. lbs.)
17 N-m (150 in. lbs.)
23 N-m (17 ft. lbs.)
23 N-m (17 ft. lbs.)
34 N m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
17 N-m (150 in. lbs.)
34 N-m (25 ft. lbs.)
Bracket
34 N m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
Bracket to I.P.
34 N m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
Pivot Bolt Nut
34 N m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
63 N-m (46 ft. lbs.)
9.5 N-m (85 in. lbs.)
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
Brake Pedal Bracket to Dash
Sleeve to Bracket
Stoplamp Switch Bracket
34 N m (25 ft. lbs.)
Push Rod to Pedal
34 N-m (25 ft. lbs.)
Push Rod Adjusting Nut
30 N-m (22 ft. lbs.)
12 N-m (100 in. lbs.)
12 N m (100 in lbs.)
12 N-m (100 in. lbs.)
to I.P. Kick Panel

or Floorpan
17 N m (100 in. lbs.)
17 N-m ( 100 in. lbs.) 12 N-m (100 in. lbs.)
Cable ClipsScrews
17 N m (150 in. lbs.)
12 N-m (100 in. lbs.)
17 N-m (150 in. lbs.)
Bolts
17 N-m (150 in. lbs.)
24 N-m (18 ft. lbs.)
6 N-m (55 in. lbs.)
Bracket to Trans.
Cable Clip to Frame
17 N-m (150 in. lbs.)
Cable Clip to Dash
6 N-m (55 in. lbs.)
27 N-m (20 ft. lbs.)
Parkinq Brake to Dash
Propshaft Parking Brake

Adjusting Nut
24 N-m (18 ft. lbs.)
40 N-m (30 ft. lbs.)

27 N-m (20 ft. lbs.)
Cable Clip to Trans. Brkt.
Flange Plate
40 N-m (30 ft. lbs.)
Drum
110 N-m (80 ft. lbs.)
44 N m (32 ft. lbs.)
Front Brake Hose to Caliper
7 N m (58 in. lbs.)
to Frame Nut
Bracket Bolt
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
10 N-m (90 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
Rear Brake Hoseto Axle Bracket
27 N m (20 ft. lbs.)
27 N-m (20 ft. lbs.)
Bracket to Axle
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)

17 N-m (150 in. lbs.) 12 N-m (100 in. lbs.)
17 N-m (150 in. lbs.)
Brake Line Attaching Nuts

Retaining ClipsScrews
Bolts
17 N-m (150 in. lbs.)

24 N-m (18 ft. lbs.)
SPECIAL TOOLS
1.
2.
3.
4.
5.
Brake B le e d e r A d a p te r
Brake B le e d e r A d a p te r
C o m b in a tio n Valve D e p re sso r
F la rin g Tool
Tube C u tte r
J-23533-B
B-09305
Figure 27Special Tool Chart
5A1-1
SECTION 5A1
HYDRAULIC BRAKE BOOSTER

SYSTEM S
manual as indicated at appropriate locations by the term inology NOTICE: See Notice on page 5A1-1 of this section.
NOTICE: This fastener is an im portant attaching part in that it could affect the performance of vital com ponents and
system, and/or could result in major repair expense. It must be replaced with one o f the same part num ber or with
an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part o f lesser quality or substitute
CONTENTS
SUBJECT
PAGE
Diagnosis of Hydro-Boost System..............................................................................................................................5A1-1

Hydro-Boost System T e sts...................................................................................................................................... 5A1-2
Vacuum B o o s te rs.........................................................................................................................................................5A1-3
Description................................................................................................................................................................. 5A1-3
Vacuum Booster Replacement................................................................................................................................ 5A1-3
Hydraulic Brake Booster (H ydro-B oost)....................................................................................................................5A1-4
Description................................................................................................................................................................. 5A1-4
Hydro-Boost R eplacem ent...................................................................................................................................... 5A1-4
Bleeding the Hydro-Boost System .......................................................................................................................... 5A1-7
S pe cifica tio n s...............................................................................................................................................................5A1-8
DIAGNOSIS OF HYDRO-BOOST SYSTEM

PROBLEM
Slow Brake Pedal
Return
POSSIBLE CAUSE
1. Excessive seal friction in booster.
2. Faulty spool action.
3. Restriction in return line from booster to
pum p reservoir.
4. Damaged input rod end.
Grabby Brakes
Booster Chattters Pedal Vibrates

2. Flush steering system while pum ping
brake pedal.
3. Replace line.
4. Replace input rod and piston assembly.
1. Faulty spool action caused by contam i

nation in system.
2. Power steering pump belt slips.
1. Flush steering system while pumping

brake pedal.
2. Tighten belt.
3. Low fluid level in power steering pump.
3. Fill reservoir and check for external

leaks.
brake pedal.
4. Faulty spool operation caused by con

tamination in system.
Accumulator
Leak-Down System
Does Not Hold Charge
CORRECTION
1. Contamination in steering hydro-boost

system.
2. Internal leakage in accum ulator system.

brake pedal.
2. Overhaul unit using accum ulator re
build kit and seal kit.
5A1-2 HYDRAULIC BRAKE BOOSTER SYSTEMS

HYDRO-BOOST SYSTEM TESTS
The Hydro-Boost system receives its source of power
fro m th e p o w e r s te e r in g s y s te m . T h e re fo re a
m alfunctioning power steering system may affect the
operation of the booster, just as a problem in the booster
may affect the steering system. Prior to performing any
tests, the following checks must be made.
1. C heck all the pow er ste ering and brake pipe
connections for leaks or restriction.
NOTICE: Power steering fluid and brake fluid

cannot bemixed. If brakesealscontact steering
fluid or steering seals contact brake fluid, seal
damage will result.
2. Check and fill the brake master cylinder with brake
fluid.
3. Check and fill the power steering reservior with
power steering fluid. If fluid contains air refer to
P O W E R S T E E R IN G (S e c. 3 B 3 ) fo r fu r th e r
diagnosis.
4. Check power steering pump belt for wear and
te n s io n . A d ju s t if n e e d e d , re fe r to PO W ER
STEERING (Sec. 3B3).
5. Check engine idle speed, refer to the vehicles
E m is s io n C o n tro l In fo rm a tio n la b e l fo r id le
specifications.
6. Check steering pump pressure. Refer to POWER
STEERING (Sec. 3B3).
A.
B.
C.
D.
E.
F.
Input Rod Seal

Power Piston Seal
H ousing Seal
Spool Valve Plug Seal
A c cu m u la to r Seal
Return Port F ittin g
B-07849
Figure 1-H ydro-B oost Seal Leak Diagnosis

NOISE DIAGNOSIS
T h e fo llo w in g n o is e s a re a s s o c ia te d w ith th e
Hydro-Boost and may or may not be cause for custom er
complaint. Some noises are normal and for the most part
temporary in nature. Other noises may be a sign of
excessive wear or the presence of air in either the booster
or the steering system.
1. A moan or low frequency hum usually accompanied
by a vibration in the pedal or steering column may
be observed during parking maneuvers or other low
speed maneuvers. This may be caused by a low
fluid level in the power steering pump or by air in the
fluid. Holding the pump at relief pressure (steering
wheel held all the way in one direction) for more
than five seconds will cause air to enter the system.
Check the fluid level and fill if needed. The system
must then sit for one hour to remove the air. If the
condition persists, refer to POWER STEERING
(Sec. 3B3).
2. A high speed fluid noise may be heard when the
brake pedal is fully depressed, this condition is
normal.
3. Whenever the accum ulator pressure is used, a
slight hiss may be noticed. It is the sound of the
hydraulic fluid escaping through the accumulator
valve, and is completely normal.
4. After the accum ulator has been emptied, and the
engine is started again, another hissing sound may
be heard during the first brake application or the
first steering maneuver. This is caused by the fluid
rushing through the accum ulator charging orifice. It
is normal and will only be heard once after the
accum ulator is em ptied. However, if this sound
continues, even though no apparent accum ulator

pressure assist was made, it could be an indication
that the accum ulator is not holding pressure and
should be checked using the procedure for the
Accum ulator Leakdown Test in this section.
BOOSTER FUNCTIONAL TEST

With the engine off, apply the brake pedal several times
until the accum ulator is completely depleted. Depress the
brake pedal using 180 N (40 lbs.) of force and start the
engine. The pedal will fall and then push back against
your foot.
ACCUMULATOR LEAKDOWN TEST

1. Start the engine and charge the accum ulator by
applying the brake pedal or by turning the steering
wheel from stop to stop. Turn off the engine and let
the vehcile sit for one hour. After one hour there
should be at least two power assisted applications
with the engine off.
2. If the reserve system will not retain a charge for one
hour, but functions norm ally immediately following
charging, the accum ulator valves are at fault and
th e b o o s te r m u st be d is a s s e m b le d and th e
accum ulator valves replaced.
3. If the accum ulator can be heard charging and
d is c h a rg in g , b u t it d o e s not hold a c h a rg e ,
d is a s s e m b le th e b o o s te r and re p la c e th e
accum ulator valves.
HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1 -3

4. Deplete the accum ulator by pressing the brake
pedal several times. If the accum ulator can has lost
its gas charge, it is possible to rotate or wobble the
a ccu m u la to r can w ith resp ect to the housing.
Replace the accum ulator assembly.
C.
SEAL LEAK DIAGNOSIS (FIGURE 1)

A. INPUT ROD SEAL. A dam aged seal will show up as
a fluid leak from the mounting bracket vent hole.
The booster must be removed from the vehicle and
d isa sse m b le d . T he in p u t rod bore s h o u ld be
checked for any scratches that may cause the leak.
If scratches are present, the housing cover must be
replaced. If no excessive scratches are present,
then the booster seal kit can be used to replace the
appropriate seals.
B. POWER PI&TON SEAL. Power piston seal damage
will be noticed by fluid leaking out at the common
master cylinder brake booster vent and possible
reduction in power assist. The booster must be
D.
E.
F.
removed from the vehicle and disassembled. The

piston should be checked for any scratches that
may be the cause of the leak. If scratches are
present, then the booster seal kit can be used to
replace the appropriate seals.
HOUSING SEAL. If the housing seal is damaged,
fluid will leak out from between the two housings.
The booster must be removed from the vehicle and
disassembled. The booster seal kit should be used
to replace the housing and input rod and power
piston seals.
SPOOL VALVE PLUG SEAL. Damage to this seal
will be noticed by fluid leaking out past the plug.
The booster need not be removed from the vehicle.
ACCUMULATOR SEAL. Damage to this seal will
result in fluid leakage past the accum ulator cap. The
seal can be replaced w hile the booster is installed
on the vehicle.
RETURN PORT FITTING. Tighten the fitting to 10
N m (7 ft. lbs.). If the leak continues, replace the
seal ring under the fitting.
VACUUM BOOSTERS
DESCRIPTION
SINGLE DIAPHRAGM MODEL
This booster is a single diaphragm vacuum suspended
unit. It may have a single function vacuum switch to
activate the brake warning light in case of low booster
vacuum or vacuum pum p m alfunction. In a norm al
operating mode, with the service brakes in the released
position, a vacuum suspended booster operates with
vacuum on both sides of its diaphragm. When the brakes
are applied, air at atmospheric pressure is admitted to
one side of the diaphragm to provide the power assist.
TANDEM DIAPHRAGM MODEL

This booster is a tandem vacuum suspended unit. It
may have a single dual function vacuum switch to activate
the brake warning light in case of low booster vacuum or
vacuum pump malfunction. In a normal operating mode,
with the service brakes in the released position, a tandem
vacuum suspended booster operates with vacuum on
both sides of its diaphragm s. W hen the brakes are
applied, air at atmospheric pressure is admitted to one
side of each diaphragm to provide the power assist.
VACUUM BOOSTER
REPLACEMENT
++

1. Mounting nuts.
2. Master cylinder.
Support the master cylinder.
3. Vacuum hose from the check valve.
4. B o o s te r p u s h ro d , re fe r to B ra k e P e d a l
R eplacem ent in HYDRAULIC BRAKES (SEC. 5A).
1.
2.
3.
4.
5.
M o u n tin g N u ts
M a s te r C y lin d e r
V a cu u m B o o s te r
B o o s te r M o u n tin g N u ts
B o o s te r P u sh ro d
B-07805
Figure 2Removing Vacuum Boosters

5. Booster m ounting nuts.
The mounting nuts must be removed from
inside the vehicle.
6. Vacuum booster.
+4* Install or Connect (Figure 2)

page5A1-1 of this section.
see
Notice on
1. Vacuum booster.
2. Booster m ounting nuts.
Nuts to 29 N m (21 ft. lbs.) for R-V-G Models.

Nuts to 24 N-m (18 ft. lbs.) for P Models.

3. Booster pushrod, refer to HYDRAULIC BRAKES
(SEC. 5A).
4. Vacuum hose.
5. Master cylinder.
6. Mounting nuts.
Tighten
Mounting nuts to 27 N m (20 ft. lbs.)
7. Release the parking brakes.
HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST)

DESCRIPTION
P 30 (42) MODEL
44
This system uses a hydraulic pump to power the system

and a pneum atic accum ulator as a reserve system.
In this system, no special fluids are used, however, care
must be taken to use the correct fluids. The master
cylinder and brake system operate on standard hydraulic
brake fluid, while the hydraulic pump operates on power
steering fluid. For diagnosis of the Hydro-Boost System,
refer to Hydro-Boost Systems Tests and Diagnosis of
Hydro-Boost System in this section.
HYDRO-BOOST REPLACEMENT
R-V AND G MODELS
1.
2.
3.
4.
5.
6.
7.

Hydraulic lines from the booster.
Nuts (1).
Master cylinder (2).
Booster pushrod. Refer to HYDRAULIC BRAKES
(SEC. 5A).
Nuts (4) and (6).
Hydro-Boost unit (3).
Gasket (5).


Pushrod retainer (10).
Retaining clip and washer.
Booster pushrod (9).
44- Install or Connect (Figures 4 and 5)
NOTICE: For steps 2 and 7 see N o tic e on
page 5A1-1 of this section.
1. Hydro-Boost unit (3).
Tighten
3.
4.
5.
6.
7.
Tighten

1. Gasket (5).
3. Nuts (4) and (6).

Booster pushrod (9).
Washer and retaining clip.
Pushrod retainer (10).
Washers (7) and nuts (1).

8. Hydraulic lines.
Bleed the booster, refer to Bleeding the Hydro-Boost
9. Release the parking brakes.
P 30 (32) MODEL
Nuts to 24 N-m (18 ft. lbs.) for R-V Models.

Nuts to 29 N-m (21 ft. lbs.) for G Models.
4. Booster pushrod. Refer to HYDRAULIC BRAKES
(SEC. 5A).
5. Master cylinder. (2).
6. Nuts (1).
Tighten
7. Hydraulic lines.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Brake pedal rod. Refer to HYDRAULIC BRAKES (SEC.
5A).
Bolt (16).
Nut (14) and washers (15).
Bolt (18).
Nuts (12) and washer (13).
Bolts (17).
HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1-5
A.
B.
1.
2.
3.
4.
5.
6.
R-V M odel
G -M odel
N ut
M a ste r C y lin d e r
H yd ro -B o o st
N ut
G asket
N ut
B-09429
Figure 3R-V and G Model Hydro-Boost Replacement
1.
2.
3.
4.
7.
8.
N ut
M aste r C y lin d e r
H yd ro -B o o st
N ut
W asher
W asher
B-07809
Figure 4P30(42) Hydro-Boost Replacement

|~K-| Install or Connect (Figure 6)
NOTICE: For steps 2, 4, 6, and 9 see N o tice
on page 5A1-1 of this section.
2. Bolts (17).
3. Washers (13) and nuts (12). Leave finger tight.
4. Bolt (18).
5. Washer (15) and nut (14). Leave finger tight.
6. Bolt (16).
7. Washer (11) and nut (10). Leave finger tight.
Tighten
Nuts (10, 14 and 12) to 34 N m (25 ft. lbs.).
8. Brake pedal rod. Refer to HYDRAULIC BRAKES (SEC.
5A).
9. Master cylinder (2).
Tighten
11. Hydraulic lines.

HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1-7

2.
3.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
M a ste r C y lin d e r
H yd ro -B o o st
N ut
W a sh er
N ut
W a sh er
N ut
W a sh er
B o lt
B o lts
B o lt
N ut
10
B-07811
Figure 6P30(32) Hydro-Boost Replacement
BLEEDING THE
HYDRO-BOOST SYSTEM
Whenever the booster is removed and reinstalled, the
steering system should be bled.
NOTICE: The pow er steering fluid and brake
fluid cannot be mixed. If the brake seals contact
steering fluid or the steering seals contact
brake fluid, seal damage will result.
1. Fill the power steering pump reservoir to the proper
level and let the fluid remain undisturbed for at least
two minutes.
2. Start the engine and run momentarily.
Add fluid, if necessary.
3. Repeat steps 1 and 2 until the fluid level remains
constant after running the engine.
4. Raise the front of the vehicle so the wheels are off the
ground.
Support the vehicle with suitable safety stands.
5. Turn the wheels from stop to stop, lightly contacting the
stops.
Add fluid, if necessary.
7. Start the engine and depress the brake pedal several
times while rotating the steering wheel from stop to
stop.
8. Turn the engine off and then pump the brake pedal 4-5
times.
9. Check fluid level, add fluid if necessary.
10. If the fluid is extremely foamy, allow the vehicle to

stand a few minutes with the engine off. Then repeat
steps 7, 8 and 9.
11. Check for the presence of air in the oil. Air in the oil will
have a milky appearance. Air in the system will also
cause the fluid level in the pump to rise when the
e n g in e
is
tu rn e d
o ff.
If
it
beco m e s
obvious that the pump will not bleed the air after a few
attempts, refer to POWER STEERING (Sec. 3B3) for
further diagnosis.
5A1 -8 HYDRAULIC BRAKE BOOSTER SYSTEMS
SPECIFICATIONS
BRAKE SYSTEMS
SYSTEM
FRONT BRAKES
REAR BRAKES
BRAKE ASSIST

R-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.04

Disc 11.86 x 1.04
Drum 11.0 x 2.00

Drum 11.0 x 2.00

Drum 11.00 x 2.00

Drum 11.00 x 2.00

Drum 11.15 x 2.75

Drum 11.15 x 2.75
Drum 13.00 x 2.50
Drum 13.00 x 3.50
Disc 13.75 x 1.54

Vacuum Dual Diaghragm
G-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.29

Disc 11.86 x 1.29
ALL MODELS
JB5
JB6
JB7
JB8
JF9
Low Drag
Low Drag
Conventional
Conventional
Conventional
Disc
Disc
Disc
Disc
Disc
11.86 x 1.29
12.50 x 1.28
12.50 x 1.28
12.50 x 1.54
14.25 x.1.54

JD3
JD5
JD6
JD7
Low Drag
Low Drag
Conventional
Conventional
Disc 11.86 x 1.29

Disc 11.86 x 1.29
Disc. 12.50 x 1.28
Disc 12.50 x 1.28
Drum
Drum
Drum
Drum
11.00 x 2.00
11.15 x 2.75
11.15 x 2.75
13.00 x 2.50
Hydraulic-Hydro-Boost
Master Cylinder to Booster
R
27 N-m (20 ft. lbs.)
V
27 N-m (20 ft. lbs.)
G
27 N-m (20 ft. lbs.)
P
27 N-m (20 ft. lbs.)
Booster to Dash or Frame
29 N-m (21 ft. lbs.)
29 N-m (21 ft. lbs.)
29 N-m (21 ft. lbs.)
24 N-m (18 ft. lbs.)
Pedal Rod Boot P 30 (32) Models
20 N-m (15 ft. lbs.)
Pivot Lever Rod Retainer
34 N-m (25 ft. lbs.)
Pivot Lever Bolt
60 N-m (45 ft. lbs.)
Booster Brackets
34 N-m (25 ft. lbs.)
Booster Brace at Dash or Rad. Supt.
17 N-m (150 in. lbs.)
Hydro Boost
-P e d a l Rod - P30 (32) Models
34 N-m (25 ft. lbs.)
Power Steering Pump to Booster Line
34 N-m (25 ft. lbs.)
Booster to Gear Line
34 N-m (25 ft. lbs.)
Return Line at Booster and Gear
34 N-m (25 ft. lbs.)
Return Line Clamp Screw
1.6 N-m (15 in. lbs.)
Line Clamp to Bracket Screw
17 N-m (150 in. lbs.)
Hose Clamp to Skirt Screw
4.5 N-m (40 in. lbs.)
Line Clamp to Frame Bolt
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
Booster to Dash or Frame
24 N-m (18 ft. lbs.)
24 N-m (18 ft. lbs.)
29 N-m (21 ft. lbs.)
29 N-m (21 ft. lbs.)
5A2-1
SECTION 5A2
HYDRAULIC FOUNDATION BRAKES

NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and
system, and/or could result in major repair expense. It must be replaced with one of the same part num ber or with
an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute
CAUTION: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by
cleaning wheel brake parts with a dry brush or with compressed air. (A water dampened cloth should be used).
Many wheel brake parts contain asbestos fibers which can become airborne if dust is created during-servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm.
CONTENTS
SUBJECT
PAGE
Disc B ra ke s................................................................................................................................................................ 5A2- 1

Description...............................................................................................................................................................5A2- 1
Brake Lining In s p e c tio n ........................................................................................................................................ 5A2- 1
Brake Lining Replacem ent....................................................................................................................................5A2- 2
Servicing the R o to r................................................................................................................................................ 5A2- 6
Rebuilding the Caliper............................................................................................................................................ 5A2- 6
Drum B ra k e s .............................................................................................................................................................. 5A2- 9
Description.............................................................................................................................................................. 5A2- 9
Brake Lining Replacem ent....................................................................................................................................5A2- 9
Servicing the Brake Drum ......................................................................................................................................5A2-10
Brake A d ju s tm e n t.................................................................................................................................................. 5A2-10
Wheel Cylinder Replacement................................................................................................................................5A2-11
Rebuilding the Wheel Cylinder..............................................................................................................................5A2-11
S pe cifica tio ns............................................................................................................................................................ 5A2-12
Special T o ols.............................................................................................................................................................. 5A2-13
DISC BRAKES
DESCRIPTION
The disc brake assembly consists of a caliper and
piston assembly, rotor, linings, and an anchor plate. The
caliper is mounted to the anchor plate, which allows the
caliper to move laterally against the rotor. The caliper is a
one-piece casting with the inboard side containing the
piston bore. A square cut rubber seal is located in a
groove in the piston bore which provides the hydraulic
seal between the piston and the cylinder wall.
OPERATION
As the brake pedal is depressed, hydraulic pressure is
applied against the piston. This pressure pushes the
inboard brake lining against the inboard braking surface
of the rotor. As the force increases against the rotor, the
c a lip e r a sse m b ly m oves in b o a rd th u s p ro v id in g a
clam ping action on the rotor.
When the brake pressure is released, the piston seal

returns to its normal position, pulling the piston back into
the caliper bore. This will create a running clearance
between the inner brake lining and the rotor.
BRAKE LINING INSPECTION

Check the outer pad by looking at each end of the
caliper (figure 1). Check the lining thickness on the inner
pad by looking down through the inspection hole in the
top of the caliper housing. Whenever the lining is worn to
about the thickness of the pad, the lining should be
removed for further measurements. The pad should be
replaced anytime the lining is worn to within 0.80 mm
(1/32-inch) of a rivet head or the pad itself.
5A2-2 HYDRAULIC FOUNDATION BRAKES
Suspend the caliper from the suspension (figure

6 ).
Im portant
Do not allow the brake components to hang from
the flexible hoses as damage to the hoses may
occur.
5. Inboard pad (6).
6. Retainer spring (5).
7. Outboard pad (7).
The disc brake pads have a wear indicator that makes a
n o ise w he n th e lin in g s w e a r to a d e g re e w h e re
replacement is required (figure 2).
Also check the flatness of the brake pads. Place the
inboard and outboard lining surfaces together and check
for a gap between the lining surfaces. This gap should not
exceed 0.13 mm (.005-inch) at the middle of the lining
surfaces. This applies to new or used brake pads.
BRAKE LINING
REPLACEMENT
3000/3100 MODELS
|*"*| Remove or Disconnect (Figure 3)
Two-thirds of the brake fluid from the master cylinder.
stands.
Mark the relationship of the wheel to the hub.
1. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
CAUTION: See Caution on page 5A2-1 of this

section.
Position a C-clamp around the outer pad and caliper
and tighten until the piston bottoms in its bore (figure
4).
2. C - clamp
3. Mounting bolts
(figure 5).
4. Caliper assembly.
2 . Sleeves
3. Bushings
4. Bushings
5. R etainer Spring
6 . Inboard Pad
7. O utboard Pad
B-07829
Figure 3Replacing Disc Brake Linings

(3000/3100 Models)
HYDRAULIC FOUNDATION BRAKES 5A2-3
Figure 4Compressing the Caliper Piston

8. Sleeves (2).
9. Bushings (3 and 4).
Inspect
The inside of the caliper assembly for signs of fluid
leakage, if found, refer to Rebuilding the Caliper in
this section.
Mounting bolts and sleeves for corrosion. Do not
attempt to polish away corrosion, replace the bolts.

Lubricate the sleeves and bushings with Delco Silicone
Lube or equivalent.
1. Bushings (3 and 4).
2. Sleeves (2).
3. Retainer spring (5) onto the inboard pad (6).
4. Inboard pad (6).
Im portant
Make sure that the brake hose is not twisted or
kinked since damage to the hose could result.
NOTICE: See N o tice on page 5A2-1 of this
section.
7. Mounting bolts
(Figure 5).
Tighten
Bolts to 48 N m (35 ft. lbs.)
Compress the pad ears to the caliper (figure 7).
tj|
Measure (Figure 8)
The clearance between the caliper ana the

steering knuckle. The clearance at each end of
the caliper should be measured individually and
added together, this total should between 0.26 0.60 mm (0.010 - 0.024-inches).
TIRES (Sec. 3E).
Lower the vehicle.
Im portant
Before moving the vehicle, pump the brake pedal
several times to make sure that the pedal is firm.
Do not move the vehicle until a firm pedal is
obtained. Check the brake fluid level in the
master cylinder after pumping the brakes.
6.
7.
8.
9.
In bo ard Pad
O u tb o a rd Pad
B o lt
S u p p o rt Key
B-07798
BENDIX MODEL
Figure 10Bendix Disc Brake Assembly

Two-thirds of the brake fluid from the master cylinder.
stands.
TIRES (Sec. 3E).
6.
7.
8.
9.
10.
CAUTION: See Caution on page 5A2-1 of this

section.
Position C - clamp and tighten until the piston bottoms
in its bore (figure 11).
2. C - clamp.
3. Bolt (8).
4. Support key (9) and spring (10).
Use a brass punch and a hammer to drive the
support key out (figure 12).
Inboard Pad
O u tb oa rd Pad
B o lt
S u p p o rt Key
S pring
A n ti-R a ttle
S pring
B-07831
Figure 9Replacing Disc Brake Linings

(Bendix Models)
Figure 11Compressing the Caliper Piston
Figure 13Suspending the Caliper

Suspend the caliper from the suspension (figure
13).
im portant
Do not allow the brake components to hang from
the flexible hoses as damage to the hoses may
occur.
6. Inboard pad (6) from the steering knuckle or rear
caliper support.
7. Anti-rattle spring (11).
Inspect
igi
The inside of the caliper assembly for signs of fluid

leakage, if found, refer to Rebuilding the Caliper in
this section.
Clean
Use a wire brush to remove any corrosion from the
machined surfaces of the steering knuckle and caliper.

Lubricate the caliper and steering knuckle (or support)
sliding surfaces and spring with Delco Silicone Lube or
equivalent.
1. Inboard pad (6) and anti-rattle spring (11).
2. Outboard pad (7) into the caliper assembly.
Important
Make sure that the brake hose is not twisted or
kinked since damage to the hose could result.
4. Spring (10) and support key (9).

Use a brass punch and a hammer to drive the
support key in (figure 14).
NOTICE: See N o tic e on page 5A2-1 o f this
section.
5. Bolt (8).
The boss on the bolt must fully fit into the circular
cutout in the key.
ll
Tighten

TIRES (Sec. 3E).
Lower the vehicle.
Important
Before moving the vehicle, pump the brake pedal
several times to make sure that the pedal is firm.
Do not move the vehicle until a firm pedal is
obtained. Check the brake fluid level in the
master cylinder after pumping the brakes.
SERVICING THE ROTOR

In the m a n u fa c tu rin g of the brake rotor all the
tolerances regarding surface finish, parallilism, and lateral
runout are held very closely. The maintenance of these
tolerances provide the surface necessary to prevent brake
roughness.
Light scoring of the rotor surface not in excess of
0.38 mm (0.15-inch) in depth is norm al. This condition
does not affect the brake operation.
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
refered to as rotor wobble .
This movement causes the brake pad and piston to be
knocked back into its bore. This results in additional
pedal travel and a vibration during braking.
Checking Lateral Runout (Figure 15)

1. Tighten the wheel bearings to eliminate all freeplay.
2. Attach a dial ind icato r to some portion of the
suspension.
The point of the styles must contact the rotor
face about 25 mm (1-inch) from the rotor edge.
3. Move the rotor one complete rotation.
The lateral runout should not exceed 0.10 mm
(0.004-inch).
4. A d ju s t th e w he el b e a rin g s , re fe r to FR O N T
SUSPENSION (Sec. 3C).
PARALLELISM
Parallelism is the measurem ent of the thickness of the
rotor at four or more points around the circum ference of
the rotor. All measurements must be made at the same
distance in from the edge of the rotor. The rotor thickness
must not vary more than 0.013 mm (0.0005-inch) from
point to point.
MACHINING
Since a ccurate co n tro l of the rotor to leran ces is
necessary for proper perform ance of the disc brakes,
machining of the rotor should be done only with precision
equipment.
All brake rotors have a minimum thickness dimension
cast into them. This dim m ension is the minimum wear
dimension and not a refinish dimension. Do not use a
brake rotor that will not meet the specifications, after
refinishing. Replace with a new brake rotor. Refer to
S p e c ific a tio n s in th is se ctio n fo r fin a l m ach in g
tolerances.
REBUILDING THE CALIPER

3000/3100 MODELS
Drain all the fluid from the caliper.
Pad the interior of the caliper with clean shop towels.
CAUTION: Do not place your fingers in front of

the piston in an attempt to catch or protect it
when applying compressed air. This could
result in serious injury.
NOTICE: Use just enough air to ease the piston
out of the bore. If the piston is blown out even
with padding provided, it may be damaged.
1. Piston (22) by directing compressed air into the caliper
fluid inlet (figure 17)
Use just enough air pressure to ease the piston
out of the bore.
2. Boot (23) (figure 18).
Use care not to scratch the housing bore.
3. Piston seal (21).
Do not use any type of metal tool.
4. Bleeder valve (20).
j j ] Clean
Bleeder valve, caliper bore, caliper passages, and
piston with denatured alcohol. Use dry, filtered
compressed air to dry parts and blow out passages.
Figure 18Removing the Boot

20. Bleeder Valve
21. Piston Seal
22. Piston
23. Boot
2. Boot (23) onto the piston (22).

3. Piston (22).
4. Boot (23) into the caliper housing counterbore using
J-26267 (figure 19).
B-07834
BENDIX MODEL
|*"*| Remove or Disconnect (Figure 20)
Figure 16Models 3000/3100 Caliper Components
L*
Drain all the fluid from the caliper.

Pad the interior of the caliper with clean shop towels.
Inspect
Piston for scoring, corrosion and any damage to the
chrome plating, replace if found.
Caliper bore for scoring, pitting, or corrosion. Use
crocus cloth to polish out any light corrosion. Replace
caliper if corrosion cannot be removed.

Tool required:
J-26267 Piston Seal Installer
Lubricate the new piston seal, caliper bore, and piston
with clean brake fluid.
1. Piston seal (21).
Make sure the seal is not twisted in the caliper
bore groove.
Figure 17Removing the Piston
Figure 19Installing the Caliper Boot
20. Bleeder Valve

21. Piston Seal
22. Piston
23. Boot
Figure 20Bendix Model Caliper Components

CAUTION: Do not place your fingers in front of
the piston in an attempt to catch or protect it
when applying compressed air. This could
result in serious injury.
NOTICE: Use just enough air to ease the piston
out of the bore. If piston is blown out even
with padding provided, it may be damaged.
1. Piston (22) by directing compressed air into the caliper
fluid inlet (figure 17).

Use just enough air pressure to ease the piston
out of the bore.
Boot (23).
Piston seal (21).
Do not use any type of metal tool.
B le e d e r valve (20).
IJI
Clean
Bleeder valve, caliper bore, caliper passages, and
piston with denatured alcohol. Use dry, filtered
compressed air to dry parts and blow out passages.
IP
Inspect
Piston for scoring, corrosion and any damage to the
chrome plating, replace if found.
Caliper bore for scoring, pitting, or corrosion. Use
corcus cloth to polish out any light corrosion. Replace
caliper if corrosion cannot be removed.

Tool required:
J-24548 Piston Seal Installer
Lubricate the new piston seal, caliper bore, piston, and
seal lips on boot with clean brake fluid.
Piston seal (21).
Make sure the seal is net twisted in the caliper
bore groove.
2. Boot (23) on tool J-24548.
Place the large diameter of the boot over the tool
first and ride the smaller diameter onto the tool.
The large diameter must then slide off the tool.
3. The large lip of the boot into the groove in the caliper
bore.
The lip of the boot must be firmly slated in the
groove.
4. Piston (22) inside J-24548 (figure 21).
5. Piston half way into its bore.
Remove J-24548.
Make sure the boot is firmly seated.
DRUM BRAKES
H old Down Spring
Lever Pivot
Lever Return Spring
A d ju s tin g Screw A ssem bly
A d ju s tin g Screw Spring
Prim ary Shoe
1. Hold Down Pins

2. Backing Plate
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Parking Brake Lever

W asher
S econdary Shoe
Retaining Ring
Shoe Guide
Parking Brake S trut
S trut Spring
A ctu ato r Lever
A ctu ato r Link
Return Spring
Return Spring
B-07791
F igure 22 Drum Brake C om po n en ts
DESCRIPTION
The drum brake assembly is a duo - servo design. With
this particular design, the force which is applied by the
wheel cylinder to the prim ary shoe is multiplied by the
prim ary lining friction to provide a large applied force to
the secondary shoe. The torque from the brake shoes is
transferred to the anchor pin and through the backing
plate, to the axle flange. Brake adjustments are automatic
and are made during reverse brake applications.
BRAKE LINING REPLACEMENT

stands.

TIRES (Sec. 3E).
CAUTION: See Caution" on page 5A2-1 of this

section.
2. Drum
Mark the relationship of the drum to the axle.
3. Return sp ring s (12 and 13).
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Shoe guide (7).

Hold down springs (14).
Hold down pins (1).
Actuator lever (10) and lever pivot (15).
Lever return spring (16).
Activator link (11).
Parking brake strut (8).
Strut spring (9).
Retaining ring (6).
Parking brake lever (4) and washer (4).

14. Shoes (5 and 19).
15. Adjusting screw assembly (17).
16. Adjusting screw spring (18).
9
Im portant
Do not interchange right and left adjusting
screws.
Inspect
All parts for discoloration due to heat, or stress.

All parts for signs of wear. Replace if necessary.
W heel c y lin d e r fo r sign s of leakage, refe r to
Rebuilding The Wheel Cylinder.
Brake drum for scoring, and machining tolerance, refer
to Servicing The Brake Drum.
H I Install or Connect (Figure 22)

Lubricate the shoe pads and adjusting screw threads
with a thin coat of white lithium grease.
1. Adjusting screw (17) and adjusting screw spring (18) to
both shoes (19 and 5).
The coils of the spring must not touch the
adjusting screw.
2. Shoe assembly.
3. Parking brake lever (3) and washer (4) into the shoe.
4. Retaining ring (6).
5. Strut spring (9) onto the parking brake strut (8).
6. Parking brake strut (8).
7. Actuator lever (10) and lever pivot (15).
8. Actuator link (11).
9. Lever return spring (16).
10. Hold down pins (1).
11. Hoid down springs (14).
12. Return springs (12 and 13).
13. Drum.
Align the marks made during disassembly.
TIRES (Sec. 3E).
Align the marks made during disassembly.
Adjust the brakes, refer to Brake Adjustment in this
section.
SERVICING THE
BRAKE DRUM
Whenever the brake drum s are removed, they should
be thoroughly cleaned and inspected for cracks, scores,
deep grooves and out-of-round.
CRACKED, SCORED, OR GROOVED DRUM

A cracked drum is unsafe for further service and must
be replaced. Do not attempt to weld a cracked drum.
Sm ooth up any slig h t scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it will
probably be necessary to machine the drum braking
surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but sh o u ld not be m ach in e d. A t th is stage,
elim inating all the grooves in the drum and smoothing the
ridges on the lining would require the removal of too much

metal and lining, while if left alone, the grooves and ridges
match and sataisfactory service can be obtained.
If brake linings are to be replaced, a grooved drum
should be machined. A grooved drum, if used with a new
lining, will not only wear the lining, but will make it
d iffic u lt, if not im p ossib le to o bta in e ffic ie n t brake
performance.
OUT-OF-ROUND OR TAPERED DRUM

An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear of other parts of the brake m echanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake drum
e x c e e d s th e s p e c ific a tio n lim its in ta p e r a n d /o r
out-of-round, the drum should be machined to true up the
braking surface. Out-of-round as well as taper and wear
can be accurately measured with an inside micrometer
fitted with proper extension rods.
When measuring a drum for out-of-round, taper and
wear, take measurments at the open and closed edges of
machined surface and at right angles to each other.
MACHINING THE DRUM

If a drum is to be machined, only enough metal should
be removed to obtain a true, smooth braking surface. If a
drum does not clean-up when m achined to a maximum
diameter, it must be replaced. Refer to Specifications in
this section. Removal of more metal will affect dissipation
of heat and may cause distortion of the drum.
All brake drum s have a maximum diameter cast into
them. This diameter is the maximum wear diameter. Do
not m achine a brake drum th a t w ill not m eet the
specification. Refer to Specifications in this section.
BRAKE ADJUSTMENT
A manual adjustment of the rear brakes is requireed
after the rear linings have been replaced. The front disc
brakes require no adjustment.
CAUTION: Refer to Caution on page 5A2-1 of

this section.
1. Remove the lanced area in the brake backing plate.
The metal lanced area must be removed from
the brake assembly.
jP
Adjust
Brake adjusting screw until the wheel can just be
turned by hand.
The brake drag should be equal at both wheels.
Back off the adjusting screw 33 notches.
Im portant
Brakes should have no drag after the screw has
been backed off about 15 notches. If a heavy
drag is p re se n t re fe r to P arking Brake
Adjustment in HYDRAULIC BRAKES (SEC.
5A).

53
54
B-07792
Figure 23Removing the Wheel Cylinder

2. Install an adjusting hole cover in the brake backing
plate.
3. Check parking brake adjustment.
WHEEL CYLINDER
REPLACEMENT
51.
52.
53.
54.
55.
1. Brake linings, refer to Brake Lining Replacement.

2. Brake pipe.
3. Bolts.
4. Wheel cylinder.
H" Install or Connect (Figure 23)

1. Wheel cylinder.
2. Bolts.
Tighten
Bolts to specification.
3. Brake pipe.
4. Brake linings, refer to Brake Lining Replacement.
5. Bleed brake system. Refer to HYDRAULIC BRAKES
(SEC. 5A).
REBUILDING THE
WHEEL CYLINDER
1. Boots (54).
2. Pistons (53).
3. Seals (52).
4. Spring assembly (55).
B-07793
Figure 24Wheel Cylinder Components

CAUTION: See Caution on page 5A2-1 in this
section.
B le e d e r Valve
Seal
P is to n
Boot
S p rin g A s s e m b ly
L*
Inspect
Cylinder bore for scoring and corrosion.
Spring assembly for signs of discoloration due to heat.
Clean
Inside the cylinder bore with crocus cloth. If the bore is
still scored replace cylinder.
Cylinder with clean brake fluid.
+3 Install or Connect (Figure 24)

Lubricate seals and cylinder bore with clean brake
fluid.
1. Spring assembly (55).
2. Seals (52).
3. Pistons (53).
4. Boots (54).
SPECIFICATIONS
BRAKE SYSTEMS
SYSTEM
FRONT BRAKES
REAR BRAKES
BRAKE ASSIST

C -M O D ELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.04

Disc 11.86 x 1.04
Drum 11.0 x 2.00

Drum 11.0 x 2.00
None (M anual Brakes)

Vacuum S ingle D iaphragm
Drum 11.00 x 2.00

Drum 11.00 x 2.00
None (M anual Brakes)

Vacuum S ingle D iaphragm
Drum 11.15 x 2.75

Drum 11.15 x 2.75
Drum 13.00 x 2.50
Drum 13.00 x 3.50
Disc 13.75 x 1.54
Vacuum Dual D iaphragm

Vacuum Dual D iaghragm
Vacuum Dual D iaphragm
H yd rau Ii c H yd ro- Boost
H y d ra u lic -H y d ro -B o o s t
G-M O DELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.29

Disc 11.86 x 1.29
ALL M ODELS
JB5
JB6
JB 7
JB8
JF9
Low Drag
Low Drag
C onventional
C onventional
C onventional
Disc
Disc
Disc
Disc
Disc
11.86
12.50
12.50
12.50
14.25
x 1.29
x 1.28
x 1.28
x 1.54
x.1.54

JD 3
JD 5
JD 6
JD 7
Low Drag
Low Drag
C onventional
C onventional
Disc
Disc
Disc.
Disc
11.86 x 1.29
11.86 x 1.29
12.50 x 1.28
12.50 x 1.28
Drum
Drum
Drum
Drum
DRUM DIAMETERS
O R IG IN A L
M AXIM U M REFINISH
11.000
11.150
12.000
13.000
11.060
11.210
12.060
13.060
11.00
11.15
11.15
13.00
x
x
x
x
2.00
2.75
2.75
2.50
H ydraulic-H ydro-B oost
ROTOR THICKNESS
R EP LAC E M E N T
(DISCARD)
11.090
11.240
12.090
13.090
M IN IM U M
AFTER R EFIN IN SH IN G
R E P LA C E M E N T
(DISC AR D )
1.480
1.230
0.980
1.465
1.215
0.965
Nm
Caliper M ounting B o lt.......................................................................................................................................48
Support Plate to K n u c k le ......................................................................... .............................................. .........16
Wheel Cylinder to Flange Plate Bolt (All Except JB5, JB6, JB76, and J B 8 ) ............................... .........5.5
Wheel C ylinder to Flange Plate Bolt (JB5, JB6, JB7 and J B 8 ) ..................................................... .........20
Rear Brake Anchor Pin (All Except JB7 and J B 8 ) ........................................................................... .........190
Rear Brake Anchor Pin (JB7 and J B 8 ) ........................................................................................................312
Brake Bleeder V a lv e s .......................................................................................................................................7
SPECIAL TOOLS
Figure 25Special Tool Chart
Ft. Lbs.
35
10
4
15
140
230
5
ENGINE 6-1
SECTION 6
ENGINE
CONTENTS
SUBJECT
PAGE
Engine............................................................................................................................................................................... 6A-1
4.3 Liter V6..................................................................................................................................................................... 6A3-1
Small B lo c k ................................................................................................................................................................... 6A4-1
7.4 Liter V8..................................................................................................................................................................... 6A5-1
6.2 Liter Diesel...............................................................................................................................................................6A6-1
4.8 Liter Diesel...............................................................................................................................................................6A7-1
Engine C o o lin g .............................................................................................................................................................6B1-1
R a d iato r......................................................................................................................................................................... 6B2-1
Fuel S ystem ..................................................................................................................................................................... 6C-1
C a rburetors................................................................................................................................................................. .6C1-1
Diesel Fuel In je ctio n .....................................................................................................................................................6C2-1
Engine E le ctrica l.............................................................................................................................................................6D-1
Drivability And Emissions.............................................................................................................................................. 6E-1
Drivability And Emissions Carburetor................................................................................................................... 6E8-1
Drivability And Emissions Diesel............................................................................................................................6E9-1
Exhaust............................................................................................................................................................................. 6F-1
Vacuum P um p.................................................................................................................................................................6H-1
GENERAL INFORMATION
Following are brief outlines of the information contained
in Section 6. Use them as a guide to help locate informa
tion more quickly.
SECTION 6A
ENGINE
T his section c o n ta in s in fo rm a tio n com m on to all
engines, including:
Use of gasket sealers.
Diagnosis (for engine mechanical).
Compression check procedure.
SECTIONS 6A3
THROUGH 6A7
4.3L V6, SMALL BLOCK,
7.4L V8, 6.2L DIESEL,
4.8L L6
These sections contain information for on-vehicle
servicing of the basic engine, such as manifold, cylinder
head, camshaft, and piston replacement.
Detailed repair information on components such as oil
pump, cylinder head, etc. is not included. Refer to the
L ig h t D u ty Truck U n it R e p a ir M a n u a l fo r th is
information.
SECTION 6B1
ENGINE COOLING
T his s e c tio n has in fo rm a tio n on c o o lin g system
components, including:
Diagnosis
Water Pump
Fan and Fan Clutch
Auxiliary Fan
Belts
Thermostat.
SECTION 6B2
RADIATORS
This section contains inform ation on radiators and
shrouds, including aluminum radiator repair procedures.
SECTION 6C
FUEL SYSTEM
This section contains inform ation on fuel system
components, including:
Accelerator controls
Fuel tanks
Air cleaners
Fuel filters (carbureted vehicles)
Fuel pump (carbureted vehicles)
Fuel tank sending unit (carbureted vehicles)
6-2 ENGINE
For fuel filter, pump, and sending unit information on
TBI equipped vehicles, refer to the Fuel and
Emissions Service Manual.
SECTION 6C1
CARBURETORS
T his se ction c o n ta in s in fo rm a tio n fo r c a rb u re to r
on-vehicle service and adjustm ents. For overhaul
information, refer to the Light Duty Truck Unit Repair
M anual.
SECTION 6C2
DIESEL FUEL INJECTION
SECTIONS 6E AND 6E8

EMISSIONS AND
DRIVEABILITY AND EMISSIONS
(CARBURETED)
This section contains information on the emissions
systems on carbureted engines, including diagnosis and
c o m p o n e n t re p la c e m e n t. For in fo rm a tio n on T B I
emissions systems, refer to the Fuel and Emissions
Service M anual.
SECTION 6E9
DRIVEABILITY AND
EMISSIONS (DIESEL)
This section contains information on the fuel injection

system used on 6.2L diesel engines, including:
Timing adjustment and other adjustment procedures.
Injection nozzle replacement and testing.
Injection pump replacement and repairs.
This section contains information on the emissions

systems of 6.2L diesel engines, including com ponent
repair. Driveability diagnosis can be found in ENGINE
(SEC. 6A).
SECTION 6D
ENGINE ELECTRICAL
SECTION 6F
EXHAUST
T h is se c tio n c o n ta in s in fo rm a tio n on e le c tric a l

components associated with engine operation, including:
Spark plug wires
Block heaters
Battery
Glow plug system
Starters
Generators
Distributors.
O n -v e h ic le se rv ic e p ro ce d u re s are give n. For
overhaul information, refer to the Light Duty Truck Unit
Repair M anual.
This section contains inform ation on the exhaust

system, including component replacement.
SECTION 6H
VACUUM PUMPS
This section contains information on vacuum pumps,
including replacement procedures and diagnosis.
ENGINE 6A-1
SECTION 6A
ENGINE
CONTENTS
SUBJECT
PAGE
General In fo rm a tio n .................................................................................................................................................... 6A- 1

Statement on Cleanliness and Care....................................................................................................................... 6A- 1
Tune-Up Inform ation................................................................................................................................................ 6A- 2
Use of RTV Sealer and Anaerobic Gasket Eliminator...........................................................................................6A- 2
Replacing Engine G a ske ts...................................................................................................................................... 6A- 2
Gasoline Engine Mechanical Diagnosis..................................................................................................................... 6A- 2
Gasoline Engine Compression C h e c k ................................................................................................................... 6A- 5
Diagnosis of Hydraulic L ifte rs ....................................................................................................................................6A- 6
Diagnosis of Diesel Engine.......................................................................................................................................... 6A- 8
Compression Check (6.2L Diesel Engine)............................................................................................................. 6A-10
Cranking Speed Check (6.2L Diesel Engine)......................................................................................................... 6A-10
Special T o ols.................................................................................................................................................................6A-11
All new General Motors vehicles are certified by the United States Environmental Protection Agency as con
forming to the requirements of the regulations for the control of air pollution from new motor vehicles. This
certification is contingent on certain adjustments being set to factory standards. In most cases, these adjustment
points either have been permanently sealed and/or made inaccessible to prevent indiscriminate or routine adjust
ment in the field. For this reason, the factory procedure for temporarily removing plugs, caps, etc., for purposes
of servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the
design. For vehicles sold in Canada and equipped with non-closed loop engines, also refer to the appropriate
Canadian service manual supplement.
GENERAL INFORMATION
STATEMENT ON
CLEANLINESS AND CARE
An engine is a combination of many machined, honed,
polished and lapped surfaces with very fine tolerances.
Whenever valve train components, cylinder head,
cylinder, crankshaft, or connecting rod components are
removed for service, they should be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating surfaces
as when removed.
Any time air cleaner, carburetor, or TBI unit is removed,
the intake opening must be covered. If a diesel engine
is being serviced, the recommended cover (J-29664-2
or J-26996-1) should be used. This will protect against
the entrance of foreign material which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.
When any internal engine parts are serviced, care and
cleanliness are important. A liberal coating of engine
oil should be applied to friction areas during assembly
to protect and lubricate the surfaces on initia l
operation. Throughout this section, it should be
understood that proper cleaning and protection of
machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
On diesel engines, whenever the fuel injection pump or

lines are removed or disconncted, care must be taken
to prevent the entry of dirt into the pump, lines, and
injectors. The entry of even small amount of dirt or
other foreign material into the fuel injection system
may cause serious damage.
It should be kept in mind, while working on the engine,
that the 12-volt electrical system is capable of violent
and damaging short circuits. When performing any
work where electrical terminals could possibly be
grounded, the ground cable of the battery should be
disconnected at the battery.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
Cover or o th e rw is e p ro te ct exposed e le c tric a l
connections to prevent damage from oil and fuel.
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen resulting in a damaged
oil pickup unit.
6A-2 ENGINE
TUNE-UP INFORMATION
All information required to tune up the vehicles engine
is given in the Engine Emission Control Label. This label
is located in the engine compartment.
Information that can be found on the label includes:
Spark plug type and gap.
Ignition timing.
Valve lash (if applicable).
Idle, fast idle, and solenoid screw speeds, as
applicable.
The proper sequence for making the adjustments.
Emission hose routing diagram (sometimes on a
separate label).
USE OF RTV SEALER

AND ANAEROBIC
GASKET ELIMINATOR
Two types of sealer are commonly used in engines
covered by this m anual. These are RTV sealer and
anaerobic gasket elim inator sealer.
It is important that these sealers be applied properly
and in the proper place to prevent oil leaks. THE TWO
TYPES OF SEALER ARE NOT INTERCHANGEABLE.
Use the sealer recommended in the procedure.
RTV (room temperature vulcanizing) sealer is used
where a non-rigid part is assembled to a rigid part.
Common examples are oil pans and rocker arm covers.
Anaerobic gasket eliminator hardens in the absence of
air. This sealer is used where two rigid parts (such as
castings) are assembled together. When two rigid parts
are disassembled and no sealer or gasket is readily
noticeable, the parts were probably assembled using
gasket eliminator.
USING RTV SEALER

1. Dont use RTV when extreme temperatures are
expected, such as exhaust manifold, head gasket or
where gasket eliminator is specified.
2. When separating components sealed with RTV, use a

rubber mallet and bump the part sideways to shear
the RTV sealer. Bumping should be done at bends
or reinforced areas to prevent distortion of parts. RTV
is weaker in shear (lateral) strength than in tensile
(vertical) strength.
Attempting to pry or pull components apart may
result in damage to the part.
3. Surfaces to be resealed must be clean and dry.
Remove all traces of oil and RTV. Clean with a
chlorinated solvent such as carburetor spray cleaner.
Dont use petroleum cleaners such as mineral spirits;
they leave a film onto which RTV wont stick.
4. Apply RTV to one of the clean surfaces. Use a bead
size as specified in the procedure. Run the bead to the
inside of any bolt holes. Do not allow the sealer in any
blind threaded holes, as it may prevent the bolt from
seating properly or cause damage when the bolt is
tightened.
5. Assemble while RTV is still wet (within 3 minutes).
Dont wait for RTV to skin over.
6. Torque bolts to specifications. Dont over-torque.
USING ANAEROBIC GASKET ELIMINATOR

1. Clean surfaces to be resealed with a chlorinated
solvent to remove all oil, grease and old material.
2. Apply a continuous bead of gasket eliminator to one
flange.
3. Spread bead evenly with your finger to get a uniform
coating on the complete flange.
4. Assemble parts in the normal manner and torque to
specifications.
REPLACING ENGINE GASKETS

CAUTION: Composite type gaskets are used in
some areas of the engine assembly. These
gaskets have a thin metal core. Use caution
when removing or handling composite gaskets
to help avoid personal injury.
GASOLINE ENGINE MECHANICAL DIAGNOSIS

The following information pertains to the basic assem
bly only. For more diagnosis information, refer to the fol
lowing:
Overheating or other cooling system problems: Refer
to COOLING (SEC. 6B).
Cranking and ignition system problems: Refer to EN

GINE ELECTRICAL (SEC. 6D).
Starting, driveability, fuel economy, etc. problems: Re
fer to DRIVEABILITY AND EMISSIONS (SEC. 6E) for
carbureted engines, or to the Fuel and Emissions Ser
vice Manual for TBI engines.
ENGINE 6A-3
GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.)

POSSIBLE CAUSE
CORRECTION
Engine Will Not Turn

Over
1. Battery, cranking system or other electri

cal problem.
2. Liquid in combustion chamber.
3. Seized engine.
1. Refer to ENGINE ELECTRICAL (SEC.

6D).
2. Remove with suction gun.
3. Repair.
Engine Cranks
Normally But Does
Not Start
1. Fuel or ignition system problem.
1. Refer to DRIVEABILITY AND EM IS

SIONS (SEC. 6E) (carbureted engines)
or Fuel and Emissions Service Man
ual (TBI engines) and ENGINE ELEC
TRICAL (SEC. 6D).
2. Repair.
3. Perform a compression test, as out
lined in this section. Repair engine as
necessary.
PROBLEM
2. Restricted exhaust system.

3. Low compression due to stuck or burned
valves, stuck rings, blown head gasket,
etc.
Rough Idle
1. Fuel, ignition system or emissions sys

tem problem.
2. Uneven cylinder compression.
3. Bent pushrod or broken valve spring.

4. Faulty engine mount.
1. Refer to DRIVEABILITY AND EM IS

ual (TBI engines) and ENGINE ELEC
TRICAL (SEC. 6D).
2. Perform a compression test, as out
lined in this section. Repair engine as
necessary.
3. Repair.
4. Repair or replace.
White Smoke
Usually caused by water vapor, which is

a normal byproduct of combustion. Usu
ally seen on cold days.
None required.
Black Smoke
Usually caused by rich fuel mixture.
Refer to FUEL SYSTEM (SEC. 6C) and/

or DRIVEABILITY AND EM ISSIONS
(SEC. 6E) (c a rb u re te d e n g in e s ) or
Fuel and Emissions Service M anual
(TBI engines).
Blue Smoke
Usually caused by oil burning in the

combustion chambers.
Refer to Excessive Oil Loss diagnosis.
Excessive Oil Loss
1. External oil leaks.

2. Im proper reading of dipstick.
3. Im proper oil viscosity.

4. Continuous high speed driving and/or
severe usage.
5. Crankcase ventilation or PCV system
malfunctioning.
6. Valve guides and/or valve stem seals
worn, or seals missing.
7. Piston rings not seated.
8. Broken or worn piston rings.
9. Piston improperly installed.
1. Tighten bolts and/or replace gaskets

and seals as necessary.
2. Check oil with vehicle on a level sur
face and allow adequate drain down
time.
3. Use recommended viscosity for prevail
ing temperatures.
4. Continuous high speed operation and/
or severe usage will normally cause de
creased oil mileage.
5. Service as necessary.
6. Ream guides and install oversize ser
vice valves and/or new valve stem
seals.
7. Allow adequate tim e for rings to seat.
8. Replace broken or worn rings as nec
essary.
9. Replace piston or repair as necessary.
6A-4 ENGINE

PROBLEM
Low Oil Pressure
POSSIBLE CAUSE
CORRECTION
1. Slow idle speed.

2. Incorrect or faulty oil pressure switch or
sensor.
3. Incorrect or faulty oil pressure gage.
4. Improper oil viscosity.
5. Diluted engine oil
1. Set idle speed to specifications.

2. Replace with proper switch or sensor.
6. Oil pump worn or dirty.

7.
8.
9.
10.
11.
12.
Valve Train Noise
Plugged oil filter

Oil pickup screen loose or plugged.
Hole in oil pickup tube.
Excessive bearing clearance.
Cracked, porous or plugged oil galleys.
Galley plugs missing or mis-installed.
1. Low oil pressure.

2.
3.
4.
5.
6.
Loose rocker arm attachments.

Worn rocker arm and/or pushrod.
Broken valve spring.
Sticking valves.
Lifters worn, dirty or faulty.
7. Camshaft worn or faulty.

8. Worn valve guides.
Engine Knocks Cold

And Continues For
Two To Three
Minutes. Knock
Increases With
Torque.
1. EFE equipped engines may have valve

knock.
2. Flywheel contacting splash shield.
3. Loose or broken torsional dam per or
drive pulleys.
4. Excessive piston to bore clearance.
5. Bent connecting rod.
Engine Has Heavy

Knock Hot With
Torque Applied.
1. Broken balancer or pulley hub.

2. Loose torque converter bolts.
3. Accessory belts too tight or nicked.
4. Exhaust system grounded.
5. Flywheel cracked or loose rivets on fly
wheel.
6. Excessive main bearing clearance.
7. Excessive rod bearing clearance.
Engine Has Light

Knock Hot In Light
Load Conditions.
1. Faulty EST or ESC system.
2.
3.
4.
5.
6.
Im proper timing.
Poor quality fuel.
Loose torque converter bolts.
Exhaust leak at manifold.
Excessive rod bearing clearance.
3. Replace with proper gage.

4. Replace with proper oil.
5. Change engine oil and filter. Repair
cause of dilution (rich mixture, etc.)
6. Clean pump and replace worn parts as
necessary.
7. Replace filter and oil.
8. Clean or replace screen as necessary.
9. Replace tube.
11. Repair or replace block.
12. Install plugs or repair as necessary.
1. Repair as necessary. (See diagnosis
for low oil pressure).
2. Inspect and repair as necessary.
4. Replace spring.
5. Free valves.
6. Refer to Diagnosis of Hydraulic Lift
ers.
7. Replace camshaft.
1. Replace EFE valve.
2. Reposition splash shield.
3. Tighten or replace as necessary.
4. Replace piston.
5. Replace connecting rod.
1. Replace parts as necessary.
2. Tighten bolts.
3. Replace and/or tension to specs as
necessary.
4. Reposition as necessary.
5. Replace flywheel.
1. Refer to D RIVEABILITY AND EM IS
ual (TBI engines).
3. Use fuel of recommended grade.
4. Tighten bolts.
5. Tighten bolts and/or replace gaskets.
6. Replace bearings as necessary.
ENGINE 6A-5

CORRECTION
POSSIBLE CAUSE
PROBLEM
Engine Knocks On
Initial Start Up But
Only Lasts A Few
Seconds.
1. Fuel pump.
2. Improper oil viscosity.
Engine Knocks At Idle

Hot
1.
2.
3.
4.
5.
1. Replace pump.
2. Install proper oil viscosity for expected
temperatures.
3. Refer to Diagnosis of Hydraulic Lift
ers.
3. Hydraulic lifter bleed down.
1.
2.
3.
4.
5.
Loose or worn drive belts.

Compressor generator bearing.
Fuel pump.
Valve train.
Im proper oil viscosity.
6. Excessive piston pin clearance.

7. Connecting rod alignment.
8. In sufficie nt piston to bore clearance.
(Cold engine piston knock usually disap
pears when the cylinders spark plug is
grounded out. Cold engine piston knock
which disappears in 1.5 minutes should
be considered acceptable.)
9. Loose torsional damper.
Tension and/or replace as necessary.

Replace as necessary.
Replace pump.
Refer to Valve Train Noise.
Install proper viscosity oil for expected
temperature.
6. Install new piston, pin and/or connect
ing rod as needed.
7. Check and replace rods as necessary.
8. Hone and fit new piston, if required.
9. Torque any or replace worn parts.
GASOLINE ENGINE COMPRESSION CHECK

GASOLINE ENGINE
COMPRESSION CHECK
1. Disconnect the primary lead from the distributor or
ignition coil. Refer to ENGINE ELECTRICAL (SEC.
6D).
2. Remove all spark plugs.
3. Block the throttle plate and choke plate (if used) wide
open.
4.
M a k e s u r e t h e b a t t e r y is f u ll y c h a r g e d .
5. Starting with the compression gage at zero, crank the

engine through four com pression strokes (four
puffs ).
6. Make the compression check at each cylinder and
record each reading.
7. If some cylinders have low compression, inject about
15 ml. (one tablespoon or about 3 squirts from a pump
type oil can) of engine oil into the combustion chamber
through the spark plug hole.
8. Minimum compression recorded in any one cylinder

should not be less than 70 per cent of highest cylinder,
and no cylinder should read less than 690 kPa (100
psi). For example, if the highest pressure in any one
cylinder is 1035 kPa (150 psi), the lowest allowable
pressure for any other cylinder would be 725 kPa (105
psi). (1035 x 70% = 725) (150 x 70% = 105).
Normal Compression builds up quickly and
evenly to s p e cifie d com pression on each
cylinder.
Piston Rings Leaking compression low on first
stroke tends to build up on following strokes but
does not reach normal. Improves considerably
with addition of oil.
Valves Leaking Low on first stroke. Does not
tend to build up on following strokes. Does not
improve much with addition of oil.
If two adjacent cylinders have lower than normal
compression, and injecting oil into cylinders
does not increase the compression, the cause
may be a head gasket leak between the
cylinders.
6A-6 ENGINE
DIAGNOSIS OF HYDRAULIC LIFTERS

PROBLEM
Momentarily Noisy
When Engine Is
Started
Intermittently Noisy
On Idle Only,
Disappearing When
Engine Speed Is
Increased
Noisy At Slow Idle Or
With Hot Oil; Quiet At
Higher Engine Speeds
Or With Cold Oil
Noisy At High Vehicle
Speeds, Quiet At Low
Speeds
Noisy At Idle,
Becoming Louder As
Engine Speed Is
Increased To 1500
RPM
POSSIBLE CAUSE
This condition is normal. Oil drains from
the lifters which are holding the valves
open when the engine is not running. It
will take a few seconds for the lifter to fill
after the engine is started.
1. Dirt in hydraulic lifter.
2. Pitted or damaged check ball.
High leak down rate.
CORRECTION
None needed.
1. Disassemble and clean.

2 . Replace the hydraulic lifter.
Replace the hydraulic lifter.
1 . High oil level Oil level above the
1 . Drain oil to proper level.
Full mark allows crankshaft counter

weights to churn the oil into foam. When
foam is pumped into the lifters, they will
become noisy since a solid column of oil
is required for proper operation.
2. Low oil level Oil level below the A dd
mark allows the oil pump to pump air at
high speeds which results in noisy lifters.
3. Oil pan bent against oil pump pickup
screen.
4. Oil pump screen bent or loose.
2. Add oil as needed.
1. This noise is not connected with lifter

malfunction. It becomes most noticeable
in the vehicle at 10 to 15 mph L (Low)
range, or 30 to 35 mph D (Drive) range
and is best described as a hashy
sound. At slow idle, it may be entirely
gone or appear as a light ticking noise in
one or more valves. It is caused by one
or more of the following:
Badly worn or scuffed valve tip and
rocker arm pad.
Excessive valve stem to guide clear
ance.
Excessive valve seat runout.
Off square valve spring.
Excessive valve face runout.
Valve spring dam per clicking on rotator.
3. Repair.
4. Repair.
ENGINE 6A-7
DIAGNOSIS OF HYDRAULIC LIFTERS (CONT.)

POSSIBLE CAUSE
CORRECTION
Noisy At Idle,
Becoming Louder As
Engine Speed Is
Increased To 1500
RPM (Continued)
2. Off square valve spring. Occasionally

this noise can be eliminated by rotating
the valve spring and valve. Crank engine
until noisy valve is off its seat. Rotate
spring. This will also rotate valve. Repeat
until valve becomes quiet. If correction is
obtained, check for an off square valve
spring.
2. If the valve spring is more than 1.6mm

( 1/ie-inch) off square, it should be re
placed.
Noisy Regardless Of
Engine Speed
1. Incorrect valve adjustm ent (excessive

lash) (en gin es w ith a d ju s ta b le valve
lash).
2. Excessive valve lash. Check for valve
lash by turning the engine so the piston
in that cylinder is on TDC of the firing
sroke. If valve lash is p re s e n t, the
pushrod can be freely moved up and
down a certain amount with rocker arm
held against valve. Excessive lash can
be caused by:
a. Worn pushrod upper end ball.
b. Bent pushrod.
c. Im proper lubrication of the pushrod.
1. Adjust as specified.
PROBLEM
d. Loose or damaged rocker arm.

e. If pushrod and rocker arm are OK, trou
ble in the hydraulic lifter is indicated.
2. Repair engine as needed.
a. Replace pushrod and rocker arm.

b. Replace pushrod.
c. R e p la ce p u sh ro d and rocke r arm .
Check lubrication system feed to the
pushrod.
d. Replace rocker arm.
e. Replace hydraulic lifter.
X = LIKELIEST CAUSES
= POSSIBLE CAUSES
M E C H A N IC A L /M A IN T E N A N C E
GASKET BLflW -BY OR SEAL LEAKAGE
FAULTY DAMPER/FLYWHEEL BALANCE
VALVE LEAKAGE
BROKEN, SCORED OR WORN PISTONS/RINGS
INCORRECT M A IN OR ROD BEARING CLEARANCE
DAMAGED CRANKSHAFT OR M AIN/ROD BEARINGS
D A M AG ED /W O RN CAMSHAFT LOBES
FAULTY LIFTER OR GUIDE PLATE
FAULTY PUSHROD OR ROCKER ARM
W O R N /M IS A LIG N E D T IM IN G GEARS, CHAIN OR KEY(S)
LOW CYLINDER COMPRESSION (380 PSI M IN .)
OIL CHANGE INTERVAL__________________________
EXTERNAL INJECTION PUM P THROTTLE LINKAGE
T IM IN G RETARDED
T IM IN G ADVANCED_________________________________________
STARTER CRANKING SPEED/BATTERIES (180 RPM M IN .)
ENGINE MOUNTS/BOLTS OR FUEL L IN E /O ILFILLTUBE CLAMPS
LONG IDLE PERIODS________________
CRACKED CYLINDER HEAD OR WALL
M IS SIN G PRECHAMBER(S)______________
ENGINE OVERLOADED/EXCESSIVE SPEED
IMPROPER STARTING PROCEDURES
DEBRIS/FLUID IN CYLINDER(S)
E L E C T R IC A L /E M IS S IO N S
INOPERATIVE GLOW PLUGS______________
FAULTY GLOW PLUG CONTROLLER/IP W IRE GROUNDS____________
FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS
INOPERATIVE GLOW PLUG CONTROLLER/RELAY__________________
SHORTED OR OPEN GLOW PLUG INHIBITO R SWITCH
NO VOLTAGE TO CONTROLLER (KEY ON)
EGR VALVE STUCK OPEN
EPR VALVE STUCK CLOSED
FAULTY EGR/EPR SOLENOIDS
MISADJUSTED OR FAULTY THROTTLE POSITION SWITCH
HOUSING PRESSURE COLD ADVANCE SOLENOID OR SWITCH
FAULTY CRANKCASE DEPRESSION REGULATOR (CDR) VALVE
CRANKCASE DEPRESSION SYSTEM HOSE CONNECTIONS
M ISADJUSTED OR FAULTY V ACUUM REGULATOR VALVE
TR A N SM ISS IO N CONVERTOR DOES NOT APPLY_________
FAULTYVACUUM PU M P(21"HG M IN .)________________
AIR S Y STEM
RESTRICTED AIR INTAKE DUCTING OR MANIFOLD
HIGH EXHAUST BACK PRESSURE_____________
CD THIN AIR IN HOT WEATHER OR HIGH ALTITUDE

O
PLUGGED AIR FILTER_________________________
LOW A M B IE N T TEMPERATURE_______________
-P* HlfiHAMRIFNTTFMPFRATIIRF
r\D
mr i
in' mi
ENGINE
MOST LIKELY/POSSIBLE CAUSES
6A-8
DIAGNOSIS OF
DIESEL ENGINE
M E C H A N IC A L /M A IN T E N A N C E
GASKET BLOW-BY OR SEAL LEAKAGE
9 10
11 12 13 14 15 16
17 18 19 20 21 22 23 24 25
X
X
26 27 28 29 30 31 32 33 34 35
FAULTY DAMPER/FLYWHEEL BALANCE

VALVE LEAKAGE
BROKEN, SCORED OR W ORN PISTONS/RINGS
DAM AG ED /W O RN CAMSHAFT LOBES
FAULTY LIFTER OR GUIDE PLATE
FAULTY PUSHROD OR ROCKER ARM
W O R N /M IS A LIG N E D T IM IN G GEARS, CHAIN OR KEY(S)
LOW CYLINDER COMPRESSION (380 PSI M IN .)
OIL CHANGE INTERVAL

EXTERNAL INJECTION PUMP THROTTLE LINKAGE
T IM IN G RETARDED
T IM IN G ADVANCED
STARTER CRANKING SPEED/BATTERIES (180 RPM M IN .)
ENGINE MOUNTS/BOLTS OR FUEL LINE/OIL FILL TUBE CLAMPS
LONG IDLE PERIODS
CRACKED CYLINDER HEAD OR WALL

M IS SIN G PRECHAMBER(S)
ENGINE OVERLOADED/EXCESSIVE SPEED
INOPERATIVE GLOW PLUGS
IMPROPER STARTING PROCEDURES
DAMAGED CRANKSHAFT OR MAIN /R OD BEARINGS
INCORRECT M A IN OR ROD BEARING CLEARANCE
E L E C T R IC A L /E M IS S IO N S
36 37 38 39 40
4
X
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35
36 37 38 39 40
FAULTY GLOW PLUG CONTROLLER/IP WIRE GROUNDS
FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS
INOPERATIVE GLOW PLUG CONTROLLER/RELAY
SHORTED OR OPEN GLOW PLUG INHIBITOR SWITCH
EGR VALVE STUCK OPEN
EPR VALVE STUCK CLOSED

FAULTY EGR/EPR SOLENOIDS, ECM, OR M AP SENSOR
MISADJUSTED OR FAULTY THROTTLE POSITION SWITCH
HOUSING PRESSURE COLD ADVANCE SOLENOID OR SWITCH
FAULTY CRANKCASE DEPRESSION REGULATOR (CDR) VALVE
CRANKCASE DEPRESSION SYSTEM HOSE CONNECTIONS
FAULTY V ACUUM PUM P (21" HG M IN .)
1 2
X
HIGH EXHAUST BACK PRESSURE
THIN AIR IN HOT WEATHER OR HIGH ALTITUDE
PLUGGED AIR FILTER
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
6A-9
RESTRICTED AIR INTAKE DUCTING OR MANIFOLD
ENGINE
TRA N SM ISS IO N CONVERTOR DOES NOT APPLY
HIGH A M B IE N T TEMPERATURE
MISADJUSTED OR FAULTY V ACUUM REGULATOR VALVE
LOW AM B IEN T TEMPERATURE
NO VOLTAGE TO CONTROLLER (KEY ON)
AIR SYSTEM
6A-10 ENGINE
6 . Crank the engine. Allow six puffs per cylinder.
7. Make the compression check at each cylinder and

record the readings.
NOTICE: Do not add oil to any cylinder during a
compression test as extensive engine damage
can result.
8 . The lowest reading cylinder should not be less than 80
percent of the highest reading cylinder. No cylinder

should read less than 2625 kPa (380 psi).
Normal: Compression builds up quickly and
evenly to s p e c ifie d co m pression on each
cylinder. Reading should be in the 2625-2760
kPa (380-400 psi) range.
Leaking: Compression low on first stroke tends to
build up on following strokes but does not reach
normal.
CRANKING SPEED CHECK

(6.2L DIESEL ENGINE)
COMPRESSION CHECK
(6.2L DIESEL ENGINE)
1.
2.
3.
4.
5.
Tools Required:
J-29664-2 or J-26996-1 Intake Manifold Cover
J-26999-10 Compression Gage Adapter
Remove the air cleaner. Install J-29664-2 or J-26996-1
over the mouth of the intake manifold.
Disconnect the wire from the fuel solenoid terminal of
the injection pump.
Disconnect wires from glow plugs then remove all glow
plugs.
Screw J-26999-10 into the glow plug hole of the
cylinder that is being checked. Connect to a suitable
compression gage (figure 1).
Make sure the batteries are fully charged, and the
engine is fully warmed up (engine oil hot).
Tool Required:
J-26999-10 Compression Gage
Cranking speed is critical for a diesel to start, either hot
or cold. Some tachometers are not accurate at cranking
speed. An alternate method of checking cranking speed
or determ ining the accuracy of a tachom eter follows:
1. Connect J-26999-10 to any cylinder.
2. Disconnect the injection pump fuel solenoid lead on
the top of the injection pump.
3. Install the digital tachometer to be checked (if desired).
4. D e p re ss th e p re s s u re re le a s e valve on the
compression gage.
5. With the aid of an assistant, crank the engine for 2 or 3
seconds to allow the starter to reach full speed, then
without stopping, count the number of puffs at the
compression gage that occur in the next 10 seconds.
Multiply the number of puffs in the 10 second period
by 12 and the resulting number will be the cranking
speed in revolutions per minute (RPM).
Example:
10 seconds = 1/6 of a minute
1
puff = 2 RPM
RPM = No. of puffs x 2 x 6 or
RPM = No. of puffs x 12
Minimum cranking speed on the 6.2L diesel engine is
100 RPM cold and 180 RPM hot. The actual cranking
speed needed will vary depending on the condition of the
engine (compression) and nozzles.
ENGINE 6A-11
SPECIAL TOOLS
'
'K
J-26999-10
2.
j . 29664
1. C o m p re s s io n G auge A d a p te r (6.2L E n gin es)

2. M a n ifo ld C ove r Set (6.2L E n gin es)
B-07603
6A-12 ENGINE
6A3-1
SECTION 6A3
4.3 LITER V6
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance o f vital
components and systems, and/or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper
retention o f this part.
CONTENTS
SUBJECT
PAGE
Description...................................................................................................................................................................6A3- 2
Engine Lubrication.................................................................................................................................................. 6A3- 2
On-Vehicle S ervice .................................................................................................................................................... 6A3- 5
Rocker Arm Cover R eplacem ent..........................................................................................................................6A3- 5
Rocker Arm and Pushrod Replacement............................................................................................................... 6A3- 5
Valve Adjustment.................................................................................................................................................... 6A3- 6
Valve Stem Seal and Valve Spring Replacement...............................................................................................6A3- 6
Intake Manifold Replacement................................................................................................................................6A3- 7
Hydraulic Lifter Replacement................................................................................................................................6A3- 9
Rocker Arm Stud Replacem ent............................................................................................................................6A3-10
Exhaust Manifold R eplacem ent............................................................................................................................6A3-11
Cylinder Head Replacement..................................................................................................................................6A3-12
Torsional Damper And Front Crankshaft Seal Replacem ent........................................................................... 6A3-13
Front Cover Replacement...................................................................................................................................... 6A3-14
Oil Pan Replacement........................................................................................................... .................................. 6A3-15
Oil Pump Replacement.......................................................................................................................................... 6A3-15
Rear Crankshaft Oil Seal Replacement............................................................................................................... 6A3-16
Rear Crankshaft Oil Seal Retainer R eplacem ent...............................................................................................6A3-16
Measuring Camshaft Lobe L if t ..............................................................................................................................6A3-17
Camshaft Replacement.......................................................................................................................................... 6A3-17
Connecting Rod And Piston R eplacem ent......................................................................................................... 6A3-20
Main Bearing Replacement....................................................................................................................................6A3-22
Oil Filter Adapter And Oil Filter Bypass Valve Replacement (Models With Engine Oil Cooler)...................6A3-23
Crankshaft Replacement........................................................................................................................................ 6A3-23
Flywheel R eplacem ent.......................................................................................................................................... 6A3-23
Engine M o u ntin g s.................................................................................................................................................. 6A3-23
Engine Replacement.............................................................................................................................................. 6A3-24
S pe cifica tio ns............................................................................................................................................................ 6A3-28
Special T o o ls .............................................................................................................................................................. 6A3-31
6A3-2 4.3 LITER V6
DESCRIPTION
4.3L engines are 90-degree V 6 type, overhead valve,
water cooled, with cast iron block and heads.
The crankshaft is supported by four precision insert
main bearings, with crankshaft thrust taken at the number
four (rear) bearing.
The camshaft is supported by four plain type bearings
and is chain driven. Motion from the camshaft is transm it
ted to the valves by hydraulic lifters, pushrods, and ball
type rocker arms. The valve guides are integral in the cyl
inder head.
The connecting rods are forged steel, with precision in
sert type crankpin bearings. The piston pins are a press fit
in the connecting rods.
The pistons are cast aluminum alloy. The piston pins
are a floating fit in the piston.
ENGINE LUBRICATION
Lubrication schem atics are shown in figures 1 and 2.
The gear type oil pump is driven from the distributor shaft,
which is gear driven from the camshaft. Oil is drawn into
the oil pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of
excessive oil pressure, a bypass valve is provided.
Filtered oil flows into the main gallery and then to the
camshaft and crankshaft bearings. The valve lifter oil
gallery supplies oil to the valve lifters. Oil flows from the
hydraulic lifters through the hollow pushrods to the rocker
arms. Oil from the overhead drains back to the crankcase
through oil drain holes.
The tim ing chain is drip fed from the front camshaft
bearing. The pistons and piston pins are lubricated by oil
splash.
4.3 LITER V6 6A3-3
6A3-4 4.3 LITER V6
Front View
Rear View
Showing Path Of Oil To Tim ing Chain.
Showing Main Gallery, Oil Filter And Crankshaft Oil Feed.
B-07860
Figure 2Engine Lubrication Diagram
4.3 LITER V6 6A3-5
DESCRIPTION
7. Power brake vacuum pipe, and move out of the way (R
and V models).
8 . Crankcase ventilation pipe at the rocker arm cover.
9. Rocker arm cover bolts.
10. Rocker arm cover and gasket.
CLEANING AND INSPECTION
All traces of old gasket from the rocker arm cover and
cylinder head.
L * Inspect
Rocker arm cover sealing surface for distortion and
damage. Replace if necessary.
INSTALLATION RIGHT SIDE

-- Install or Connect (Figure 3)
2. Rocker arm cover bolts and washers.
Tighten
Rocker arm cover bolts to 11.3 N m (100 in. lbs.).

Wiring harness to the rocker cover.
Spark plug wires, clips, and brackets (G models).
Diverter valve, hoses, and bracket (G models).
Air cleaner and heat stove tube.
Engine cover (G models).
Battery negative cable.
INSTALLATION LEFT SIDE
ROCKER ARM COVER

REPLACEMENT
REMOVAL RIGHT SIDE

1 . Rocker arm cover and gasket.
Tighten

1.
2.
3.
4.
5.
6.
7.
8.
9.

Air cleaner and heat stove tube.
Diverter valve, bracket and hoses (G models).
Spark plug wire bracket at the side of the cylinder head
(G models).
Spark plug wires and clip at the rear of the cylinder
head (G models).
Wiring harnesses at the rocker arm cover. Move out of
the way.
Rocker arm cover bolts.
Rocker arm cover and gasket.
REMOVAL LEFT SIDE

1.
2.
3.
4.
5.
6.

Oil fill tube (G models).
AIR pipe and check valve (G models).
Generator rear bracket (G models).
Air conditioning compressor, and lay aside (R and V
models).
7.
8.
9.
10.
Rocker arm cover bolts to 11.3 N m (100 in. lbs.).

Crankcase ventilation pipe.
Power brake vacuum pipe (R and V models).
Air conditioning compressor (R and V models).
Generator rear bracket (G models).
AIR pipe and check valve (G models).
ROCKER ARM AND PUSHROD

REPLACEMENT
4- +
1. Rocker arm cover, as outlined previously.

2. Rocker arm nut.
If only the pushrod is to be replaced, back the
rocker arm nut off until the rocker arm can be
swung away from the pushrod. Then pull the
pushrod out.
3. Rocker arm with ball.
4. Pushrod.
6A3-6 4.3 LITER V6

Important
Store used components in order so they can be
reassembled in the same location.
Inspect
Rocker arms and balls at their mating surfaces. These
surfaces should be smooth and free from scoring or
other damage.
Rocker arm areas which contact the valve stems and
the sockets which contact the pushrods. These areas
should be smooth and free of damage and wear.
Pushrods for bending. Roll the pushrod on a flat
surface to determine if it is bent. Replace if necessary.
Ends of the pushrods for scoring or roughness.
Install or Connect
1. Pushrod. Make sure the pushrod seats properly in the
hydraulic lifter.
Im portant
When new rocker arms and/or balls are installed,
coat their bearing surfaces with Molykote or
equivalent.
3. Rocker arm nuts.
Exhaust: 2, 3, 4.
Intake: 4, 5, 6 .
6 . Install the rocker arm cover as outlined previously.
VALVE STEM SEAL AND

VALVE SPRING
REPLACEMENT
Adjust
Valves as outlined later.
Rocker arm cover, as outlined previously.
VALVE ADJUSTMENT
Remove the rocker arm cover as outlined previously.
Crank the engine until the mark on the torsional
damper lines up with the O mark on the timing tab
and the engine in the number one firing position. This
may be determined by placing fingers on the number
one valve as the mark on the damper comes near the
O mark on the timing tab. If the rocker arms are not
moving, the engine is in the number one firing position.
If the rocker arms move as the mark comes up to the
timing tab, the engine is in the number four firing
position and should be turned over one more time to
reach the number one position.
With the engine in the number one firing position as
determ ined above, the follow ing valves may be
adjusted:
Exhaust: 1, 5, 6 .
Intake: 1, 2, 3.
(Even numbered cylinders are in the right bank; odd
numbered cylinders are in the left bank, when viewed
from the rear of the engine).
4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all lash is
removed. This can be determined by rotating the
pushrod while turning the adjusting nut (figure 4).
When the play has been removed, turn the adjusting
nut in one full additional turn (to center the lifter
plunger).
Crank the engine one revolution until the timing tab
O mark and vibration damper mark are again in
alignment. This is the number four firing position. The
following valves may be adjusted:
++

Tools Required:
J-23590 Air Adapter.
J-5892-B Spring Compressor.
1.
2.
3.
4.

Rocker arms, as outlined previously.
Spark plugs.
Valve keepers (20).
Install J-23590 into the spark plug hole.
Apply compressed air to hold the valves in place.
Install a rocker arm nut (figure 6 ).
2 0 . Valve K e ep e r
21 . C ap
2 2 . S h ie ld
23. O -R ing Seal

24. Seal
25. D am pe r
20
oo
22 23
26.
27.
28.
29.
25
B-07609
Figure 5Valves and Components
4.3 LITER V6 6A3-7

+- Install or Connect (Figures 5, 6, and 7)
1.
2.
3.
F igure 6C om pre ssin g th e V alve S p rin gs

Use J-5892-B to compress the valve spring
(figure 6).
Remove the valve keepers.
Carefully release the spring tension. Remove
J-5892-B.
5. Cap (21) and/or rotator (28), shield (22) and spring (26)
with damper (25).
6. O-ring seal (23), and seal (24) (intake valve only).
5.
Tools Required:
J-23994-01 Adapter Cup.
J-23738-A Vacuum Pump.
New seal (24) (intake valve only). Install the seal over
the intake valve stem and seat it against the head.
Spring (26) with damper (25), sheild (22) and cap (21)
and/or rotator (28).
New O-ring seal (23) and valve keepers (20).
With air pressure applied to the cylinder with
J-23590, compress the spring with J-5892-B
(figure 6).
Lubricate the O-ring seal with engine oil. Install
the seal on the valve stem. Make sure the seal is
not twisted.
Install the valve keepers. Use grease to hold
them in place.
Carefully release spring pressure. Make sure the
valve keepers stay in place.
Remove J-5892-B and J-23590.
Check each O-ring seal for leakage (figure 7).
Place the suction cup furnished with
J-23738-A over the shield.
Connect J-23738-A to the suction cup and
apply a vacuum. Watch the vacuum pump
gage. No air should be able to leak past
the seal. If the seal will not hold a vacuum,
it may have been damaged or improperly
installed.
Spark plugs.
E3 Adiust
Valves, as outlined previously.
INTAKE MANIFOLD
REPLACEMENT
B-07869
Figure 7Testing the Valve Seals

2. Engine cover (G models).
3. Air cleaner and heat stove tube.
Drain the cooling system.
4. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D).
5. Accelerator, cruise control, and TVS cables and
bracket.
%. Cruise control transducer, if equipped.
7. Air conditioning compressor, and lay aside (G models).
8 . Air conditioning compressor rear brackets at the
manifold (R and V models).
9. Generator bracket at the manifold.
10. Idler pulley bracket at the manifold (G models).
11. Fuel and vacuum lines and electrical connections at
the TBI unit and manifold.
12. Heater pipe.
13. Upper radiator hose.
14. Power brake vacuum pipe.
15. Coil wires.
16. EGR vacuum line.
6A3-8 4.3 LITER V6
C. RTV Sealant
B-07872
Figure 8Intake Manifold

17.
18.
19.
20.
21.
Sensors with bracket on right side.

Wiring harness on right side. Move out of the way.
Transmission dipstrick tube (if equipped) (G models).
Intake manifold bolts.
Intake manifold and gaskets.
Clean
Old gasket and RTV from the block, heads, and intake
manifold. Remove all RTV that is loose or will cause
interference at assembly.
Excessive carbon deposits from the exhaust and EGR
passages.
Excessive scale and deposits from the coolant
passages.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Transmission dipstick tube (if equipped) (G models).

Wiring harness.
Sensors with bracket.
EGR vacuum line.
Coil wires.
Power brake vacuum pump.
Upper radiator hose.
Heater pipe.
Fuel and vacuum lines and electrical connections at
the TBI and manifold.
14. Idler pulley bracket (G models).
Inspect
Manifold for cracks and gasket surface damage.

1. Gaskets to the cylinder head.
2. RTV to the front and rear sealing surfaces on the block
(figure 8). Apply a 5 mm (3/i6-inch) bead of RTV (part
number 1052366 or equivalent) to the front and rear of
the block as shown. Extend the bead 13 mm (1/2-inch)
up each cylinder head to seal and retain the gaskets.
3. Intake manifold to the engine.
4. Intake manifold bolts.
Tighten
Intake manifold bolts to 48 N m (35 ft. lbs.). Use
the tightening sequence shown in figure 9.
INITIAL TIGHTENING SEQUENCE
FINAL TIGHTENING SEQUENCE

A. Front Of Engine
B-07873
Figure 9Intake Manifold Bolt Tightening Sequence
4.3 LITER V6 6A3-9
40.
41.
42.
43.
44.
45.
46.
47.
Bolt
Retainer
N uts
Balls
Rocker A rm s
Pushrods
R e stricto r
H ydrualic L ifte r
B-07611
Figure 10Hydraulic Lifters and Components

15. Generator bracket.
16. Air conditioning compressor rear brackets (R and V
models).
17. A ir c o n d itio n in g c o m p re s s o r (G m odels).
18. C ruise co n tro l tran sdu ce r, if e quipped.
19. Accelerator, cruise control, and TVS cables and
bracket.
21. Air cleaner and heat stove tube.'
Fill the cooling system with the proper coolant.
HYDRAULIC LIFTER
REPLACEMENT
Remove or Disconnect (Figures 10)
1. Rocker arm cover, intake manifold, and pushrods, as
outlined previously.
2. Bolts (40).
3. Retainer (41) with restrictors (46).
4. Hydraulic lifters.
Remove the hydraulic lifters one at a time and
place them in an organizer rack. The lifters must
be installed in the same bore from which they
were removed.
I*
Inspect
Hydraulic lifter body for scuffing or scoring. If the lifter

body wall is worn or damaged, the mating bore in the
block should also be checked.
Check the fit of each hydraulic lifter in its mating bore

in the block. If the clearance is excessive, try a new
lifter.
Roller for freedom of movement.
Roller for flat spots, pits and missing or broken needle
bearings. If worn, pitted, or damaged, the mating
camshaft lobe should also be checked.
Hydraulic Lifter Repair

Refer to the proper unit repair manual.

1. Hydraulic lifters to the block. Lubricate the lifter
rolleran d body w ith Engine O il S u p p le m e n t or
equivalent.
Im portant
W hen any new hydraulic lifte rs or a new
camshaft is installed, change the engine oil and
filter. Engine Oil Supplement (or equivalent)
should be added to the engine oil.
R eplace all h yd ra u lic lifte rs when a new
camshaft is installed.
2. Retainer (41) with restrictors (46).
3. Bolts (40).
Tighten
Bolts (40) to 16.4 N m (145 in. lbs.).
4. Intake manifold, as outlined previously.
5. Pushrod, as outlined previously.
6A3-10 4.3 LITER V6
Adjust
ROCKER ARM STUD

REPLACEMENT
Tool Required:
J-5802-01 Rocker Arm Stud Remover.
1. Rocker arm cover and rocker arm, as outlined
previously.
2. Rocker arm stud.
|~n~| Install or Connect (Figures 12 and 13)

Tools Required:
J-5715 Reamer (0.003-inch oversize) or
J-6036 Reamer (0.013-inch oversize).
Place J-5802-01 over the rocker arm stud.

Install a nut and flat washer.
J-6880 Rocker Arm Stud Installer.
Turn the nut to remove the stud (figure 11).

NOTICE: Do not attem pt to install an oversize
rocker arm stud without reaming the stud hole
as this could damage the cylinder head.
Ream the hole to the proper size for the replacement
oversize rocker arm stud. Use J-5715 for 0.003-inch
oversize studs; J-6036 for 0.013-inch oversize stud
(figure 12).
Coat the lower end (press-fit area) of the rocker arm
stud with hypoid axle lubricant.
1. Rocker arm stud. Use J-6880 (figure 13). Stud is
installed to proper depth when the tool bottoms on the
cylinder head.
2. Rocker arm, as outlined previously.
Adjust
Figure 12Reaming the Rocker Arm Stud Bore

(Typical)
4.3 LITER V6 6A3-11
CAST IRON MANIFOLD

(TYPICAL)
STAINLESS STEEL
MANIFOLD
60.
61.
62.
63.
Heat Shield
W asher
Tab W asher
Bolt/Stud
62 61
B-07612
Figure 14Exhaust Manifold
EXHAUST MANIFOLD
REPLACEMENT

Raise the vehicle. Support with suitable safety stands.
3. Exhaust pipe at the manifold.
Lower the vehicle.
4. Oxygen sensor wire (left side manifold). Do not remove
the oxygen sensor from the manifold unless it is to be
replaced.
5. Air conditioning com pressor rear bracket at the
manifold, if equipped (R and V models - left side
manifold).
6. Power steering pump bracket at the manifold (G
models - left side manifold).
7. Heat stove pipe (right side manifold).
8. AIR pipe at the diverter valve (R and V models - right
side manifold).
9. Diverter valve bracket (R and V models - right side

manifold).
10. Dipstick tube bracket at the manifold (G models
right side manifold).
11. AIR hose at the check valve.
12. Exhaust manifold bolts, washers, heat shield (left side
manifold), and tab washers.
13. Exhaust manifold.
j y l Clean
Mating surfaces on the manifold and head.
Threads on the exhaust manifold bolts.

1. Exhaust manifold, bolts, washers, heat shield (left side
manifold), and tab washers.
Bolts on center exhaust tube to 36 N-m (26 ft.

lbs.).
Bolts on front and rear exhaust ubes to 28 N-m
(20 ft. lbs.).
6A3-12 4.3 LITER V6

Bend the tab washers over the heads of all bolts.
3. Dipstick tube bracket at the manifold (G models - right
side manifold).
4. Diverter valve bracket (R and V models - right side
manifold).
5. AIR pipe at the diverter valve (R and V models - right
side manifold).
6. Heat stove tube (right side manifold).
7. Power steering pump bracket at the manifold (G
models - left side manifold).
8. Air conditioning compressor rear bracket, if equipped
(R and V models - left side manifold).
9. Oxygen sensor wire (left side manifold).
10. Exhaust pipe to the manifold.
Lower the vehicle.
CYLINDER HEAD
REPLACEMENT
REMOVAL R AND V MODELS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1.
2.
3.
4.
5.
6.
0 0 0
B-07874
Figure 15Cylinder Head Bolt Tightening Sequence

9. Wiring harness, clip and ground strap at the rear of the
head (right cylinder head).
10. Fuel pipes and bracket at the rear of the cylinder head
(left cylinder head).
11. Coolant sensor wire (left cylinder head).
12. Cruise control transducer bracket (left cylinder head).
14. Spark plugs.
15. Pushrods, as outlined previously.

Intake manifold, as outlined previously.
Exhaust manifold, as described previously.
AIR pipe at the rear of the head.
Generator mounting bolt at the cylinder head (right
cylinder head).
Power steering pump and brackets from the cylinder
head, and lay aside (left cylinder head).
Air conditioning compressor and brackets, and lay
aside (left cylinder head).
Spark plug wires from the brackets.
Coolant sensor wire (left cylinder head).
Cruise control transducer bracket (left cylinder head).
Dipstick tube at the cylinder head, and move aside
(right cylinder head).
Spark plugs.
Pushrods, as outlined previously.
Cylinder head bolts.
Cylinder head.
Gasket.
16. Cylinder head bolts.

Engine cover.
Exhaust manifold, as described previously.
AIR pipe at the rear of the head.
AIR pump mounting bolt and spacer at the cylinder
head (right cylinder head).
7. Engine accessory bracket bolts and studs at the
cylinder head. For left cylinder head removal, it may be
necessary to loosen the remaining bracket bolts to
provide clearance for head removal.
8. Spark plug wires at the brackets.
4 i FRONT
REMOVAL - G MODELS
++
17. Cylinder head.

18. Gasket.
CLEANING, INSPECTION, AND REPAIR

Clean
Carbon deposits from combustion chambers.
All traces of old head gasket from cylinder head and
block.
Cylinder head bolt threads and threads in the block.
Inspect
Sealing surfaces of the block and cylinder head for
nicks, heavy scratches, or other damage.
Cylinder Head Repair

Refer to the proper Unit Repair Manual.
INSTALLATION R AND V MODELS

1. Head gasket.
If a steel gasket is used, coat both sides of the
gasket with sealer. Spread the sealer thin and
even.
Do not use sealer on composition steel-asbestos
gaskets.
Place the gasket over the block dowel pins with
the bead up.
2. Cylinder head. Carefully guide the cylinder head into
place over the dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder head
bolts with sealing com pound (GM part num ber
1052080 or equivalent) and install finger-tight.
4.3 LITER V6 6A3-13
Cylinder head bolts, a little at a time, using the

sequence shown in figure 15. Proper torque is 90
N m (65 ft. lbs.).
A djust
9.
10.
11.
12.
13.
14.
15.
16.
17.
Valves, as outlined previousiy.

Spark plugs.
Dipstick tube (right cylinder head).
Cruise control transducer bracket (left cylinder head).
Coolant sensor wire (left cylinder head).
Spark plug wires.
Air conditioning compressor and brackets (left cylinder
head).
Power steering pump and brackets (left cylinder head).
Generator mounting bolt (right cylinder head).
AIR pipe.
Exhaust manifold, as outlined previously.
Figure 16Removing the Torsional Damper

TORSIONAL DAMPER AND

FRONT CRANKSHAFT
SEAL REPLACEMENT
IN STALLATIO N G MODELS
-" Install or Connect (Figure 15)

1. Head gasket.
even.
gaskets.
the bead up.
2. Cylinder head. Carefully guide the cylinder head into
Tighten
sequence shown in figure 15. Proper torque is 90
N m (65 ft. lbs.).
A djust
6. Spark plugs.
7. Cruise control transducer bracket (left cylinder head).I
8. Coolant sensor wire (left cylinder head).
9. Fuel pipes and bracket (left cylinder head).
10. Wiring harness, clip, and ground strap (right cylinder
head).
11. Spark plug wires.
12. Engine accessory bracket bolts and studs.
13. AIR pump mounting bolt and spacer (right cylinder
head).
14. AIR pipe.
15. Exhaust manifold, as outlined previously.
17. Engine cover.
1.
2.
3.
4.
5.
6.
Tool Required:
J-23523-E Torsional Damper Puller and Installer.
Fan belts, fan, and pulley.
Fan shroud assembly.
Accessory drive pulley.
Torsional damper bolt.
Torsional damper. Use J-23523-E (figure 16).
Front crankshaft seal. Pry out with a large screwdriver.
Take care not to distort the timing cover.
Crankshaft key, if necessary.
Inspect
Oil seal contact area on the torsional damper shaft for
grooving and roughness. Replace if necessary.

Tools Required:
J-35468 Seal Installer.
J-23523-E Torsional Damper Puller and Installer.
1. Crankshaft key, if removed.
2. Front crankshaft seal. Use J-35468 (figure 17). The
open end of the seal faces inside the engine. Coat the
seal lips with engine oil.
NOTICE: The in ertia w e ig h t s ectio n o f the
torsional dam per is assembled to the hub with a
rubber type material. The correct installation
procedures (w ith the p ro p er tool) m ust be
follow ed or m ovem ent o f the inertia w eight
section o f the hub will destroy the tuning o f the
torsional damper.
3. Stud (item A, figure 18) to the crankshaft. Thread the
stud fully into the tapped hole in the crankshaft.
6A3-14 4.3 LITER V6
4. Torsional damper over the end of the stud. Align the

keyway in the torsional dam per shaft with the
crankshaft key.
5. Bearing, washer and nut (figure 18).
FRONT COVER REPLACEMENT
++
1. Torsional damper, as outlined previously.
Turn the nut to pull the vibration damper into

place.
2. Water pump. Refer to ENGINE COOLING (SEC. 6B1).
Remove the tool.
4. Front cover bolts.
3. Oil pan, as outlined later.
Use a small amount of RTV sealant to seal the

torsional damper key to crankshaft joint.
5. Front cover.
6. Torsional damper bolt and washer.
7. Front crankshaft oil seal from the front cover. Pry out
with a screwdriver. Take care not to distort the front
cover.
Tighten
6. Front cover to block gasket.
Clean
7. Accessory drive pulley.
Old gasket from the front cover, and block.
8. Fan shroud assembly.
Inspect
9. Fan pulley, fan, and fan belts.
Front cover for distortion and damage. Replace if

necessary.

Tool Required:
1. Front crankshaft oil seal. Use J-35468 (figure 19). The
2. Front cover gasket to the front cover. Use gasket
cement to hold them in place.
3. Front cover and bolts.
Tighten
Front cover bolts to 11.3 N m (100 in. lbs.).

5. Water pump.
4.3 LITER V6 6A3-15

I*
Inspect
Oil pan gasket for damage. Replace if necessary.
Apply sealant (GM part number 1052080 or equivalent)

to the front cover to block joint and to the rear
crankshaft seal to block joint. Apply the sealant for
about 25 mm (1-inch) in both directions from each of
the four corners.
1. Oil pan gasket to the oil pan.

2. Oil pan to the engine.
3. Oil pan bolts, nuts, and reinforcements.
Tighten
Oil pan bolts to 11.3 N m (100 in. lbs.).
Oil pan nuts at corners to 22.6 N m (200 in. lbs.).
4. Strut rods at the engine mounts (V models with
automatic transmission).
5. Starter.
6. Strut rod brackets at the front engine mountings.
7. Strut rods at the flywheel cover.
8. Converter housing under pan (models with automatic
transmission).
9. Exhaust crossover pipe.
Lower the vehicle.
10. Proper quantity and grade of engine oil.
OIL PUMP REPLACEMENT
70. G a ske t
|+"| Remove or Disconnect

B-07884
Figure 20Oil Pan
1. Oil pan, as outlined previously.

2. Oil pump to main bearing cap bolt.
3. Oil pump.
OIL PAN REPLACEMENT

A one piece type oil pan gasket is used.

1.
2.
3.
4.
5.
6.
7.
8.
9.

Drain the engine oil.
Exhaust crossover pipe.
Torque converter cover (m odels with autom atic
transmission).
Strut rods at flywheel cover.
Strut rod brackets at the front engine mountings.
Starter.
Strut rods at engine mounts (V models with automatic
transmission).
Oil pan bolts, nuts, and reinforcements.
Oil pan and gasket.
Clean
Gasket surfaces on the engine and oil pan.
1 * Inspect
Oil pump pickup tube for looseness. If the tube is loose
in the oil pump body, replace it, as outlined in the
proper unit repair manual. A loose pickup tube can
result in an air leak and loss of oil pressure.
Oil Pump Repair

1. Oil pump to the engine. Align the slot in the oil pump
shaft with the tang on the distributor shaft. The oil
pump should slide easily into place. No gasket is used.
Oil pump to main bearing cap bolt to 90 N m (65

ft. lbs.).
6A3-16 4.3 LITER V6
REAR CRANKSHAFT
OIL SEAL REPLACEMENT
REAR CRANKSHAFT
OIL SEAL RETAINER
REPLACEMENT

1. Transmission.
2. Clutch and flywheel or flexplate, as equipped.
NOTICE: Care should be taken when removing
the rear crankshaft oil seal so as not to nick the
crankshaft sealing surface.

1. Transmission.
4. Screws (80) and nuts (81).
3. Rear crankshaft oil seal. Insert a screwdriver into the

notches provided in the seal retainer and pry the seal
out (figure 21). Take care not to damage the crankshaft
sealing surface.
L*
Inspect
Chamfer on crankshaft for grit, loose rust, and burrs.
Correct as necessary.
Clean
Seal running surface on the crankshaft with a
non-abrasive cleaner.

Tool Required:
1. Rear crankshaft oil seal (figure 22).
Lubricate the inner and outer diameter of the
seal with engine oil.
Install the seal on J-35621.
Position J-35621 against the crankshaft. Thread
the attaching screws into the tapped holes in the
crankshaft.
Tighten the screws securely with a screwdriver.
This will ensure that the seal is installed squarely
over the crankshaft.
Turn the handle until it bottoms.
Remove J-35621.
3. Transmission.
5. Seal retainer (82).

6. Gasket (84).
out (figure 21).
Clean
Gasket surfaces on block and seal retainer.
-+ Install or Connect (Figures 21 and 23)

Whenever the seal retainer is removed, a new retainer
gasket and rear crankshaft oil seal must be installed.
1. Gasket (84) to the block. It is not necessary to use
sealant to hold the gasket in place.
Tighten
Screws (80) and nuts (81) to 15.3 N m (135 in.
lbs.).
5. Rear crankshaft oil seal as outlined previously.
7. Transmission.
4.3 LITER V6 6A3-17
A.
80.
81.
82.
83.
84.
Rear o f B lock
Screw
Nut
Retainer
Stud
Gasket
B-07614
Figure 23Rear Crankshaft Oil Seal Retainer
MEASURING CAMSHAFT
LOBE LIFT
Tool Required:
J-8520 Camshaft Lobe Lift Indicator.
1. Remove the rocker arm as outlined previously.
2. Refer to figure 24. Position the dial indicator (part of
J-8520) so the plunger rests on the pushrod end, as
shown. Make sure the pushrod is in the lifter socket.
3. Rotate the crankshaft slowly in the direction of rotation
until the lifter is on the heel of the cam lobe. At this
point, the pushrod will be in its lowest position.
4. Set dial indicator on zero, then rotate the crankshaft
slowly, or attach an auxiliary starter switch and
bump the engine over, until the pushrod is in fully
raised position.
Im portant
Whenever the engine is cranked remotely at the
starter, with a special jumper cable or other
means, the distributor primary lead should be
disconnected from the ignition coil.
5. Compare the total lift recorded from the dial indicator
with specifications.
6 . If c a m s h a ft re a d in g s for all lob es are w ith in
specifications, remove dial indicator assembly.
Install the rocker arm and adjust the valves as
previously outlined.
CAMSHAFT REPLACEMENT
R AND V MODELS
++
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Tool Required:
J-5825-A Crankshaft Sprocket Puller.
Air cleaner.
Fan, shroud, and radiator. Refer to ENGINE COOLING
(SEC. 6B1) and RADIATOR (SEC. 6B2).
Generator.
Rocker arm covers, as outlined previously.
Water pump. Refer to ENGINE COOLING (SEC. 6B1).
Torsional damper, as outlined previously.
Front cover, as outlined previously.
Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D).
Pushrods and hydraulic lifters, as outlined previously.
Align the timing marks (figure 26).
Camshaft sprocket bolts.
Camshaft sprocket and timing chain. The sprocket is a
light interference fit on the camshaft. Tap the sprocket
on its lower edge to loosen it.
Screws (88) and thrust plate (87).
Crankshaft sprocket (if required). Use J-5825-A (figure
27).
Engine mount through-bolts.
Raise the engine.
Camshaft.
6A3-18 4.3 LITER V6
87. T h ru s t Plate
88. S crew
B-07615
Figure 25Camshaft and Components

Install two or three 5/ie-18 bolts 100-125 mm (4-5
inches) long into the camshaft threaded holes.
Use these bolts to handle the camshaft (figure
28).
Pull the camshaft from the block. Use care to
prevent damage to the camshaft bearings.
Cleaning, Inspection And Repair

Clean, inspect and repair or replace the camshaft and
related components, as outlined in the proper unit repair
manual.
The u nit rep air m anual also d escrib e s ca m sh aft
bearing replacement.
-- Install or Connect (Figures 25 through 28, 36,

and 37)
T o o l R e q u ir e d :
J-5590 Crankshaft Sprocket Installer.

Coat the camshaft lobes and journals with a high
q u a lity engine oil su p p le m e n t (GM Engine Oil
Supplement or equivalent).
B-09549
Figure 27Replacing the Crankshaft Sprocket
4.3 LITER V6 6A3-19
Replace all hydraulic lifters, change the engine

oil and filter, and add GM Engine Oil Supplement
(or equivalent) to the engine oil whenever a new
ft
Adjust

Water pump.
Generator.
Fan, shroud, and radiator. Refer to ENGINE COOLING
(SEC. 6B1) and RADIATOR (SEC. 6B2).
17. Air cleaner.
9.
10.
11.
12.
13.
14.
15.
16.
G MODELS
1. Two or three 5/ie-18 bolts 100-125 mm (4-5 inches) long

into the camshaft threaded holes. Use these bolts to
handle the camshaft.
2. Camshaft to the engine (figure 28). Handle the
camshaft carefully to prevent damage to the camshaft
bearings.
Lower the engine.
3. Engine mount through-bolts.
Tighten
Through-bolts or nuts to specifications. Refer to
figures 36 and 37.
4. Crankshaft sprocket (if removed). Use J-5590 (figure
27). Make sure the timing mark faces outside.
5. Thrust plate (87) and screws (88).

6. Camshaft sprocket and timing chain.
Im portant
Line up the tim ing marks on the camshaft
sprocket and crankshaft sprocket (figure 26).
7. Camshaft sprocket bolts.
Tighten

8. Hydraulic lifters and pushrods, as outlined previously.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Tool Required:
J-5825-A Crankshaft Sprocket Puller.
Hydraulic lifters and pushrods, as outlined previously.
Outside air duct.
Power steering reservoir.
Upper fan shroud bolts.
Radiator. Refer to RADIATOR (SEC. 6B2).
Hood release cable at the latch.
Upper fan shroud.
Water pump.
Camshaft sprocket and timing chain. The sprocket is a
Screws (88) and thrust plate (87).
Crankshaft sprocket (if necessary). Use J-5825-A
(figure 27).
Camshaft.
Install two or three 5/ie-18 bolts 100-125 mm (4-5
inches) long into the camshaft tapped holes. Use
these bolts to handle the camshaft (figure 28).
Cleaning, Inspection and Repair

manual.
The unit re p air m anual also d e scrib e s ca m sh aft

Tool Required:
J-5590 Crankshaft Sprocket Installer.
6A3-20 4.3 LITER V6

q u a lity engine oil su p p le m e n t (GM Engine Oil
Two or three 5/is-18 bolts 100-125 mm (4-5 inches) long
into the camshaft threaded holes. Use these bolts to
handle the camshaft.
2. Camshaft to the engine (figure 28). Handle the
bearings.
3. Crankshaft sprocket. Use J-5590 (figure 27). Make sure
the timing mark faces outside.
4. Thrust plate (87) and screws (88).
Tighten
Im portant

Tighten
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Water pump.
Upper fan shroud.
Hood release cable.
Outside air ducts.
ft
A djust

17. Rocker arm covers, as outlined previously.
18. Intake manifold, as outlined previously
CONNECTING ROD AND

PISTON REPLACEMENT
1.
2.
3.
4.
5.
Tool Required:
J-5239 Guide Set.
Cylinder head, as outlined previously.
Oil pan, as outlined previously.
Oil pump, as outlined previously (if necessary).
Ridge or deposits from the upper end of the cylinder
bores.
Turn the crankshaft until the piston is at BDC.
Place a cloth on top of the piston.
Perform the cutting operation with a ridge
reamer.
Turn the crankshaft until the piston is at TDC.
Remove the cloth and cuttings.
Connecting rod cap. Check the connecting rod and
cap for identification marks. Mark the parts if required.
The connecting rod and cap must be kept together as
mating parts.
A. G uide Rod
B. Thread P rotector
B-05269
Figure 29Replacing the Connecting Rod and

Piston (Typical)
6. Connecting rod and piston.
Attach J-5239 to the connecting rod bolts (figure
29).
Use the long guide rod of J-5239 to push the
connecting rod and piston out of the bore.
7. Connecting rod bearing.
Cleaning, Inspection, And Repair

Clean, inspect and repair or replace the components as
necessary. Measure connecting rod bearing clearance,
piston clearance, ring clearances, etc. Refer to the proper
unit repair manual.
The unit repair manual contains information on:
Connecting rod and piston.
Piston rings.
Connecting rod and crankpin.
Cylinder bores.
-+ Install or Connect (Figures 29 through 32)

Tools Required:
J-5239 Connecting Rod Guide Set.
J-8037 Ring Compressor.
Make sure the cylinder walls are clean. Lubricate the
cylinder wall lightly with engine oil.
Make sure the piston is installed in the matching
cylinder.
1. Connecting rod bearings.
Be certain that the bearing inserts are of the
proper size.
Install the bearing inserts in the connecting rod
and connecting rod cap.
4.3 LITER V6 6A3-21

6
ENGINE LEFT
ENGINE FRONT
ENGINE RIGHT
A.
B.
C.
D.
Oil Ring Rail Gaps

2nd Compression Ring Gap
Notch In Piston
Oil Ring Spacer Gap
(Tang In Hole Or Slot W ith Arc)
E. Top Compression Ring Gap
B-07895
Figure 30Piston Ring End Gap Locations
Figure 32Measuring Connecting Rod Side Clearance

The piston must be installed so that the notch in
the piston faces the front of the engine (figure
30).
Place the piston in its matching bore. The
connecting rod bearing tang slots must be on the
side opposite the camshaft. Using light blows
with a hammer handle, tap the piston down into
its bore (figure 31). At the same time, from
beneath the vehicle guide the connecting rod to
the crankpin with J-5239 (figure 29). Hold the
ring compressor against the block until all rings
have entered the cylinder bore.
Remove J-5239 from the connecting rod bolts.
Lubricate the bearings with engine oil.

2 Pistpn and connecting rod to the proper bore.
With the connecting rod cap removed, install
J-5239 onto the connecting rod studs.
Locate the piston ring end gaps as shown in
figure 30. Lubricate the piston and rings with
engine oil.
Without disturbing the ring end gap location,
install J-8037 over the piston (figure 31).
Im portant
Each connecting rod and bearing cap should be
marked, beginning at the front of the engine.
Cylinders 1, 3 and 5 are at the left bank and, 2, 4
and 6 are the right bank. The numbers on the
connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If
a connecting rod is ever transposed from block
or cylinder to another, new connecting rod
bearings should be fitted and the connecting rod
should be numbered to correspond with the new
cylinder number.
Measure
Connecting rod bearing clearance. Refer to the

proper unit repair manual.
3. Connecting rod cap and bearing.
4. Connecting rod cap nuts.
Tighten
Connecting rod cap nuts to 60 N m (45 ft. lbs.).
Measure
Connecting rod side clearance. Use a feeler
gage between the connecting rod and crankshaft
(fig u re 32). The c o rre c t c le a ra n c e is
0.006-0.014-inch.
5. Oil pump (if removed), as outlined previously.
6A3-22 4.3 LITER V6
Figure 33Removing the Main Bearing Insert

6. Oil pan and cylinder head, as outlined previously.
MAIN BEARING REPLACEMENT
Remove the tool.

2. Lower main bearing inserts to the main bearing caps.
Make sure the inserts are of the proper size.
Apply engine oil to the inserts.
1.
2.
3.
4.
5.
6.
Tool Required:
J-8080 Main Bearing Remover/Installer.
Spark plugs.
Oil pump, as outlined previously.
Main bearing caps.
Check the main bearing caps for location
markings. Mark the caps if necessary. The caps
must be returned to their original locations
during assembly.
Lower main bearing inserts from the main bearing
caps.
Upper main bearing inserts.
Insert J-8080 into the crankshaft oil hole (figure
33).
Rotate the crankshaft to turn the bearing insert
out of the block.

Clean, inspect, and repair or replace the components
as required. Refer to the proper unit repair manual. The
unit repair manual contains information on:
Crankshaft.
Main and connecting rod bearings.

Tool Required:
J-8080 Main Bearing Remover/Installer.
1. Upper main bearing inserts.
Insert J-8080 into a crankshaft main bearing oil
hole (figure 33).
Apply engine oil to inserts of the proper size.
Insert the plain end (without the bearing tang) of
the insert between the crankshaft and the
notched side of the block.
Rotate the crankshaft to roll the insert into the
block.
Measure
Main bearing clearance. Refer to the proper unit
repair manual. If the engine is in the vehicle, the
crankshaft must be supported upward to remove
any clearance from the upper bearing. The total
clearance can then be measured between the
lower bearing and journal.
3. Main bearing caps (except rear cap) and bolts to the
block.
4. Rear
Tighten
Main bearing cap bolts to 100 N m (75 ft. lbs.).
main bearing cap.
Apply engine oil to the bearing insert.
Install the rear main bearing cap and bolts.
Tighten the bolts temporarily to 14 N-m (10 ft.
lbs.).
Measure
Crankshaft end play, as follows:
Tap the end of the crankshaft first rearward
then forward with a lead hammer. This will
lin e up th e re a r m ain b e a rin g and
crankshaft thrust surfaces.
Tighten the rear main bearing cap bolts to
100 N-m (75 ft. lbs.).
W ith the c ra n k s h a ft fo rce d fo rw a rd ,
measure at the front end of the rear main
bearing with a feeler gage (figure 34). The
proper clearance is 0.002-0.006-inch.
If correct end play cannot be obtained, be
certain that the correct size rear main
bearing has been installed. Production
engines may have rear main bearings that
are 0.008-inch wider across the thrust
faces than standard. Refer to the proper
unit repair manual for more information.
4.3 LITER V6 6A3-23

Tighten
3. Oil cooler lines.
4. Oil filter.
Add engine oil as needed.
CRANKSHAFT REPLACEMENT
1. Remove the engine, as outlined later.
2. Refer to the proper unit repair manual for crankshaft
replacement procedures.
FLYWHEEL REPLACEMENT
Rembve or Disconnect
Transmission, flywheel housing, and clutch.
Flywheel bolts.
Flywheel.
Clean
90.
91.
92.
93.
Seal
Gasket
Oil Filter Adapter
Bolt
Mating surfaces of crankshaft and flywheel. Remove

any burrs.
L*
Flywheel for burning, scoring, warping, and wear.

Replace the flywheel if necessary. Do not machine the
flywheel.
B-07904
Flywheel ring gear for worn or broken teeth.
Figure 35Oil Filter Adapter

8. Oil pump, as outlined previously.
10. Spark plugs.
OIL FILTER ADAPTER AND

OIL FILTER BYPASS VALVE
REPLACEMENT (MODELS WITH
ENGINE OIL COOLER)
Inspect
Flywheel Ring Gear Replacement

1. Use a torch to heat the gear around the entire
circumference, then drive the gear off the flywheel,
using care not to damage the flywheel.
NOTICE: Never heat starter gear to red heat as
this will change metal structure.
2. Uniformly heat the flywheel gear to temperature which
will expand the gear to permit installation. Temperature
must not exceed 204C (400F).
3. As soon as the gear has been heated, install on the
flywheel.
1. Oil filter.
+ 4-
Inspect
Bypass valve spring and fiber valve for proper
o p e ra tio n , cra cks, or o th e r d am ag e. If
replacement is required, the bypass valve and oil
filter adapter must be replaced as an assembly,
as outlined following.
2. Oil cooler lines.
3. Bolts (93).
4. Oil filter adapter (92).
5. Gasket (91) and seal (90).

1. New gasket (91), new seal (90) and oil filter adapter
(92) to the block.
2. Bolts (93).
Install or Connect
1. Flywheel.
2. Flywheel bolts.
Tighten
Flywheel bolts to 100 N m (75 ft. lbs.).
3. Clutch, flywheel housing, and transmission.
ENGINE MOUNTINGS
NOTICE: Broken or deteriorated mountings can
cause misaligned and eventual destruction of
certain drive train components. When a single
m o u n tin g b re ak ag e occurs, the re m ain in g
mountings are subjected to abnormally high
stresses.
6A3-24 4.3 LITER V6

INSPECTING ENGINE MOUNTINGS
Front Engine Mountings
NOTICE: When raising or supporting the engine
for any reason, do not use a jack under the oil
pan, any sheet m etal or crankshaft pulley. Due
to the small clearance between the oil pan and
the oil pum p screen, jacking against the oil pan
may cause it to be b en t against the pum p
screen, resulting in a dam aged oil pickup unit.
1. Raise the engine to remove weight from the mountings
and to place a slight tension on the rubber cushion.
Observe both mountings while raising the engine.
2. Replace the mounting if the following conditions exist:
Hard rubber surface covered with heat check
cracks.
Rubber cushion separated from the metal palte
of the mounting.
Rubber cushion split through the center.
3. If there is movement between a metal plate of the
mounting and its attaching points, lower the engine
and tighten the bolts or nuts attaching the mounting to
the engine, frame, or bracket.
Rear Mountings
1. Push up and pull down on the transmission tailshaft.
Observe the transmission mounting.
Rubber cushion separated from the metal plate
of the mounting.
Mounting bottomed out (tailshaft can be moved
up but not down).
3. If there is relative movement between a metal plate of
the mounting and its attaching point, tighten the bolts
or nuts attaching the mounting to the transmission or
crossmember.
FRONT MOUNTING REPLACEMENT

may cause it to be bent against the pum p

1. Mounting assembly.
NOTICE: See N otice on page 6A3-1 of this
section.
2. Mounting assembly bolts, nuts, and washers.
Tighten
Fasteners to specifications. Refer to figures 36
and 37.
3. Engine mount through-bolt and nut. Lower the engine
until the bolt can be inserted. Install the nut.
Tighten
Through-bolt or nut to specifications. Refer to
figures 36 and 37.
REAR MOUNTING RELACEMENT

4-+ Remove or Disconnect (Figures 38 and 39)
for any reason, do not use a ja ck under the oil
Support the rear of the engine to relieve the weight on
the rear mountings.
1. Mounting to crossmember nut(s) and washer(s).
2. Mounting to transmission bolts and washers.
Raise the rear of the engine only enough to permit
removal of the mounting.
3. Mounting.
-*3 in s ta ll o r C o n n e c t (F ig u re s 38 a n d 39)
1. Mounting.
Lower the rear of the engine.
section.
Tighten
and 39.
Support the engine with a suitable jack. Do not load

the engine mounting.
1. Engine mounting through-bolt and nut.
ENGINE REPLACEMENT
R AND V MODELS
NOTICE: Raise the engine only enough for

sufficient clearance. Check for interference
between the rear of the engine and the dash
panel which could cause distributor damage.
Raise the engine only enough to permit removal of the
engine mounting.
1.
2.
3.
4.
5.
6.

Hood.
Air cleaner.
All accessory drive belts.
Fan and water pump pulley.
Radiator and shroud. Refer to RADIATOR (SEC. 6B2).
4.3 LITER V6 6A3-25
7. Heater hoses at the engine.

8. Accelerator cruise control, and detent linkage (if used)
from the carburetor.
9. Air conditioning compressor (if used) and lay aside.
10. Power steering pump (if used) and lay aside.
11. Engine wiring harness from the engine.
12.
13.
Fuel line.
Vacuum lines from the intake manifold.
Drain the crankcase oil.
14. Exhaust pipes rom the manifolds.

15. Strut rods at the engine mountings ( V models with
16. Flywheel or torque converter cover.
17. Wiring along oil pan rail.
18. Starter.
19. Wiring for fuel gage.
20. Converter to flex plate bolts (automatic transmission).
Lower the vehicle.
Support the transmission.
Figure 37Front Engine Mounting (G Models)
6A3-26 4.3 LITER V6
R MODELS
C. 55 N m (40 Ft. Lbs.)
V MODELS
B-07616
Figure 38Rear Engine Mounting (R and V Models)

Attach a suitable lifting fixture to the engine.
21. Bell housing to engine bolts.
22. Engine mounting to frame bolts.
NOTICE: See N o tice on page 6A3-1 o f this

section.
2. Engine mounting to frame bolts.
23. Hood.
2 4 . E n g in e .

1. Engine to the vehicle.
Fasteners to specifications. Refer to figure 36.

3. Bell housing to engine bolts. Remove the transmission
support.
4. Converter to flex plate bolts.
5. Fuel gage wiring.
6. Starter.
9. Strut rods at the engine mountings (V models with
10. Exhaust pipes to the manifolds.
Lower the vehicle.
11 . Vacuum lines to the intake manifold.
12. Fuel line.
13. Engine wiring harness.
14. Power steering pump (if used).
15. Air conditioning compressor (if used).
16. Accelerator, cruise control, and detent linkages.
17. Heater hoses.
18. Radiator and shroud. Refer to RADIATOR (SEC. 6B2).
19. Accessory drive belts.
20. Air cleaner.
21. Hood.
22. Proper quantity and grade of coolant and crankcase
oil.
4.3 LITER V6 6A3-27

G MODELS
|+ + | Remove or Disconnect
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.

Glove box.
Engine cover.
Drain the coolant.
Outside air duct.
Power steering fluid reservoir.
Hood release cable.
Upper fan shroud.
Fan and pulley.
Air cleaner.
Cruise control transducer.
Vacuum hoses at the intake manifold.
Accelerator, cruise control, and TVS cables (if used).
TBI unit.
Distributor cap.
Diverter valve.
Coolant hose at the intake manifold.
PCV valve.
Other necessary vacuum hoses and wires.
Air conditioning compressor and brace. Refer to AIR
Upper half of engine dipstick tube.
Oil filler tube.
Transmission dipstick tube.
Accelerator cable at the dipstick tube.
Fuel hoses at the fuel pump.
Power steering pump.
Headlamp bezels and grille.
Upper radiator support.
Lower fan shroud and filler panel.
Hood latch support.
Condenser.
Drain the crankcase.
Exhaust pipes at the manifolds.
S tru t rods at the to rq ue co nve rte r or flyw he el
underpan.
Torque convertor or flywheel cover.
Starter.
F lexplate to torque co n ve rte r bolts (autom atic
transmissions).
Bell housing to engine bolts.
Engine mounting through bolts.
Lower the vehicle and support the transmission.
Engine.

section.
2. Engine mounting through-bolts.
Tighten
Through-bolts or nuts to specifications. Refer to
figure 37.
4. Flex plate to torque converter bolts (autom atic

transmissions).
5. Starter.
6. Torque converter or flywheel cover.
7. Strut rods.
8. Exhaust pipes.
Lower the vehicle.
9. Condenser.
10. Hood latch support.
11. Lower fan shroud and filler panel.
12. Upper radiator support.
13. Headlamp bezels and grille.
14. Pump.
15. Fuel hoses.
16. Accelerator cable at the dipstick tube.
17. Transmission dipstick tube.
18. Oil filler tube.
19. Upper half of engine dipstick tube.
20. Air conditioning compressor and brace. Refer to AIR
21. Vacuum hoses and wires.
22. PCV valve.
23. Coolant hose at the intake manifold.
24. Diverter valve.
25. Distributor cap.
26. TBI unit.
27. Accelerator, cruise control, and detent cables.
28. Vacuum hoses at the intake manifold.
29. Cruise control servo.
30. Air cleaner.
31. Fan and pulley.
32. Upper fan shroud.
33. Radiator. Refer to RADIATOR (SEC. 6B2).
34. Upper fan shroud bolts.
35. Hood release cable.
36. Power steering fluid reservoir.
37. Outside air duct.
38. Glove box.
oil.
40. Engine cover.
Evacuate and charge the air conditioning system.
6A3-28 4.3 LITER V6
SPECIFICATIONS
ENGINE SPECIFICATIONS
All Specifications are in INCHES unless otherwise noted.
GENERAL DATA:
Type
Displacement
RPO
Bore
Stroke
Compression Ratio
Firing Order
Oil Pressure
V6
4.3L (262 Cu. In.)
LB4
4.00
3.48
9.3:1
1-6-5-4-3-2
10 psi @ 500 RPM; 30-35 psi @ 2000 RPM
CYLINDER BORE:
Diameter
Out Of
Round
Service
3.9995-4.0025
0.001 (Maximum)
0.002 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.001 (Maximum)
Production
Service Limit
0.0007-0.0017
0.0027 (Maximum)
Production
Service
Thrust Side
Relief Side
Taper
PISTON:
PISTON RING:
C
o
M
P
R
F
S
c
0
1
O
N
0
1
L
Groove
Production
Top
Clearance
Service Limit
Production
Gap
Groove
Clearance
Gap
0.0012-0.0032
2nd
Hi Limit Production + 0.001
Top
0.010-0.020
2nd
0.010-0.025
Service Limit
Production
Service Limit
Production
Service Limit
0.002-0.007
0.015-0.055
Hi Production +0.010
Production
Service Limit
0.9270-0.09273
0.0002-0.0007
0.001 (Maximum)
0.0008-0.0016 Interference
PISTON PIN:
Diameter
Clearance
In Piston
Fit In Rod
4.3 LITER V6 6A3-29
ENGINE SPECIFICATIONS (CONT.)
All specifications are in INCHES unless otherwise noted.
4.3L
DISPLACEMENT:
CRANKSHAFT:
#1
#2, #3
#4
Production
Service Limit
Production
Service Limit
#1
#2, #3
#4
#1
#2, #3
#4
Diameter
Main
Journal
Taper
Out Of
Round
Production
Main
Bearing
Clearance
Service Limit
Crankshaft End Play

Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
Taper
Crankpin
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
2.4484-2.4493
2.4481-2.4490
2.4479-2.4488
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
0.0008-0.0020
0.0011-0.0023
0.0017-0.0032
0.0010-0.0015
0.0010-0.0025
0.0025-0.0035
0.002-0.006
2.2487-2.2497
0.0005
0.001 (Maximum)
0.0005
0.001 (Maximum)
0.0013-0.0035
0.0030
0.006-0.014
CAMSHAFT:
Intake
Exhaust
Lobe
Lift + 0.002
Journal Diameter
Camshaft End Play
0.357
0.390
1.8682-1.8692
0.004-0.012
VALVE SYSTEM:
Hydraulic
1.50:1
Lifter
Rocker Arm Ratio
Valve Lash
Intake
Exhaust
One Turn Down From Zero Lash
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
45
46
0.002 (Maximum)
1/32-1/l 6
1/l6-3/32
0.0010-0.0027
0.0010-0.0027
High Limit Production +0.001
2.03
76-84 lbs. @ 1.70-in.
194-206 lbs. @ 1.25-in.
Face Anqle (Intake & Exhaust)

Seat Angle (Intake & Exhaust)
Seat Runout (Intake & Exhaust)
Seat Width
Stem
Clearance
Valve
Spring
(Outer)
Valve
Spring
Damper
Production
Service
Free Length
Pressure
lbs. @ in.
Closed
Open
Installed Height
+ 1/32"
Free Length
Approx. # of Coils
123/32
1.86
4
6A3-30 4.3 LITER V6
ITEM
Rocker Arm Cover B o lt s ...........................................................................
Intake Manifold B o lts ..................................................................................
Exhaust Manifold Bolts
Center Two B o lts..................................................................................
All O th e r s .............................................................................................
Cylinder Head B o lts ....................................................................................
Torsional Damper B o lt...............................................................................
Front Cover B o lts ........................................................................................
Oil Pan N u ts .................................................................................................
Oil Pan Bolts.................................................................................................
Oil Pump B o lt...............................................................................................
Rear Crankshaft Oil Seal Retainer Screws and N u t s ........................
Camshaft Sprocket B o lts ...........................................................................
Connecting Rod Cap N uts.........................................................................
Oil Filter Adapter Bolts ...........................................................................................................................................
Main Bearing Cap B o lts . ...................................................................................................................................
Oii Pump Cover B o lt s ...............................................................................
Flywheel B o its .............................................................................................
Spark P lu g s .................................................................................................
Water Outlet B o lts ......................................................................................
Water Pump B o lt s ......................................................................................
Flywheel Housing B o lts .............................................................................
Camshaft Thrust Plate S c re w s ................................................................
Hydraulic Lifter Restrictor Retainer B o lts ..............................................
Oil Pan Studs to Oil Seal Retainer or C ra n k c a s e ......................................................
..................
..................
..................
..................
..................
..................
..................
...............................
..................
..................
..................
..................
..................
...............................
..................
..................
..................
..................
..................
..................
..................
...............................
...............................
Nm
11.3
48
FT. LBS.
35
IN. LBS.
100
36
28
90
95
11.3
22.6
11.3
90
15.3
23
60
20
100
9.0
100
30
28
40
44
11.9
16.4
1.7
26
20
65
70
65
100
200
100
135
17
45
15
75
80
75
22
21
30
32
105
145
15
4.3 LITER V6 6A3-31
SPECIAL TOOLS
J-23523-E
J-5802 01
J-5892-B
10
J-5715
11
J-6036
12
0)
J-6880
J-23590
13
J-35468
1.
2.
3.
4.
5.
6.
7.
8.
Torsional Dam per Remover and In staller

Valve S pring C om pressor
A ir A dapter
C rankshaft Seal In sta lle r and C entering Tool
Main Bearing Replacer
P iston Ring C om pressor
G uide Set
Vacuum Pump
9.
10.
11.
12.
13.
14.
15.
16.
J-5825-A
Stud Remover
Reamer (0.003-inch oversize)
Stud In sta lle r
C rankshaft Gear Puller
C rankshaft Gear In staller
Dial In d ica to r A dapter
Rear C rankshaft Seal In staller
B-07617
6A3-32 4.3 LITER V6
6A4-1
SECTION 6A4
SMALL BLOCK
m anual as indicated at appropriate locations by the term inology NOTICE: See Notice on page 6A4-1 of this section.
NOTICE: All engine fasteners are important attaching parts in that they could affect the perform ance of vital
com ponents and systems, and/or could result in m ajor repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part of
retention of this part.
CONTENTS
SUBJECT
PAGE
Description................................................................................................................................................................... 6A4- 2
Engine Lubrication................................................................................................................................................... 6A4- 2
On-Vehicle S ervice ..................................................................................................................................................... 6A4- 5
Rocker Arm Cover Replacem ent.......................................................................................................................... 6A4- 5
Rocker Arm and Pushrod Replacement................................................................................................................6A4- 6
Valve Adjustment..................................................................................................................................................... 6A4- 6
Valve Stem Seal and Valve Spring Replacement.......................................................... .....................................6A4- 7
Intake Manifold Replacement................................................................................................................................ 6A4- 8
Hydraulic Lifter Replacement................................................................................................................................ 6A4- 9
Rocker Arm Stud R eplacem ent............................................................................................................................ 6A4-10
Exhaust Manifold R eplacem ent............................................................................................................................ 6A4-11
Cylinder Head Replacement.................................................................................................................................. 6A4-12
Torsional Damper and Front Crankshaft Seal Replacement.............................................................................6A4-13
Front Cover Replacement.......................................................................................................................................6A4-14
Oil Pan Replacement...............................................................................................................................................6A4-14
Oil Pump Replacement...........................................................................................................................................6A4-15
Rear Crankshaft Oil Seal Replacem ent................................................................................................................6A4-15
Rear Crankshaft Oil Seal Retainer R eplacem ent............................................................................................... 6A4-16
Measuring Camshaft Lobe L if t .............................................................................................................................. 6A4-17
Camshaft Replacement...........................................................................................................................................6A4-17
Connecting Rod and Piston Replacement............................................................................................................6A4-19
Oil Filter Bypass V a lv e ...........................................................................................................................................6A4-20
Main Bearing Replacement.................................................................................................................................... 6A4-21
Flywheel R eplacem ent...........................................................................................................................................6A4-22
Engine M o u n tin g s...................................................................................................................................................6A4-22
Engine Replacem ent........................................................ ...................................................................................... 6A4-23
S pe cifica tio n s............................................................................................................................................................. 6A4-32
Special T o o ls............................................................................................................................................................... 6A4-35
6A4-2 SMALL BLOCK
DESCRIPTION
Small block engines covered by this manual are availa
ble in two displacements; 5.0L (305 cu. in.) and 5.7L (350
cu. in.).
Small block engines are 90-degree V8 type, overhead
valve, water cooled, with cast iron block and heads.
The crankshaft is supported by five precision insert
five (rear) bearing.
The camshaft is supported by five plain type bearings
ted to the valves by hydraulic lifters, pushrods, and ball
type rocker arms. The valve guides are integral in the cyl
inder head.
The pistons are cast alum inum alloy. The piston pins
ENGINE LUBRICATION
Lubrication schem atics are shown in figures 1 and 2.
The gear type oil pump is driven from the distributor shaft,
which is gear driven from the camshaft. Oil is drawn into
the oil pump through a pickup screen and pipe.
excessive oil pressure, a bypass valve is provided.
Filtered oil flows into the main gallery and then to the
The tim ing chain is drip fed from the front camshaft
splash.
SMALL BLOCK 6A4-3
6A4-4 SMALL BLOCK
SMALL BLOCK 6A4-5
ON-VEHICLE SERVICE
5. Bolt
6. W a sh er
R o cke r A rm C over
8. G a sket
10. N u t
TBI ENGINES
CARBURETED ENGINES
B-07620
Figure 3Rocker Arm Cover
ROCKER ARM COVER

REPLACEMENT
REMOVAL TBI ENGINES
1.
2.
3.
4.
5.
6.

Air cleaner.
Crankcase ventilation hoses at the rocker arm covers.
Wiring harnesses from the clips, and move aside.
Components as follows for right rocker arm cover:
AIR hose from check valve (G models).
D iverter valve and hoses from bracket (G
models).
PCV valve.
Upper dipstick bracket (G models).
Heat stove pipe.
Components as follows for left rocker arm cover.:

Generator rear brace (G models).
Power brake vacuum pipe and move aside (R
and V models).
Air conditioning compressor, and lay aside (R
and V models).
8. AIR pipe at manifold (G models).
REMOVAL CARBURETED ENGINES

1.
2.
3.
4.
5.

Air cleaner.
Crankcase ventilation hoses at the rocker arm covers.
Wiring harnesses from the clips, and move aside.
6A4-6 SMALL BLOCK

6.
7.
8.
9.
10.
Diverter valve with bracket and hoses.

AIR check valve.
Oil fill tube (right side cover).
Heat stove pipe (right side cover).
Components as follows for left rocker arm cover:
Decel valve and bracket (G models).
Vacuum pipe from EFE valve.
Power brake vacuum pipe, and move aside.
Air co nd itio nin g com pressor rear brace (if
equipped).
11. Rocker arm cover nuts, reinforcements, and wire clips.

Clean
All traces of old gasket from the rocker arm cover and
cylinder head.
Inspect
I*
Rocker arm cover sealing surface for distortion.

5.
6.
7.
8.
9.
10.
11.
12.

REPLACEMENT
++

2. Rocker arm nut.
pushrod out.
4. Pushrod.
INSTALLATION TBI ENGINES
Im portant

1. Rocker arm cover and new gasket.
Oil fill tube (right side cover).

AIR check valve.
Diverter valve, bracket, and hoses.
Wiring harnesses to the rocker arm clips.
Crankcase ventilation hoses.
Air cleaner.

Inspect
6.
7.
8.
9.
10.
Bolts to 11.3 N m (100 in. lbs.).

AIR pipe at manifold (G models).
Components as follows for left rocker arm cover:
Air conditioning compressor (R and V models).
Power brake vacuum pipe (R and V models).
Generator rear brace (G models).
Components as follows for right rocker arm cover:
Heat stove pipe.
Upper dipstick bracket (G models).
PCV valve.
Diverter valve and hoses (G models).
AIR hose to check valve (G models).
Wiring harnesses to the rocker arm clips.
Air cleaner.
INSTALLATION CARBURETED ENGINES

2. Reinforcements, wire clips, nuts, and stud (if used).
&
Tighten
Nuts to 7.3 N m (65 in. lbs.).

3. Components as follows for left rocker arm cover:
A ir co nd itio nin g com pressor rear brace (if
equipped).
Power brake vacuum pipe.
Vacuum pipe to EFE valve.
Decel valve and bracket.
4. Heat stove pipe (right side cover).
Rocker arms and balls at their mating surfaces.

These surfaces should be smooth and free from
scoring or other damage.
Rocker arm areas which contact the valve stems
and the sockets which contact the pushrods. These
areas should be smooth and free of damage and
wear.
su rfa ce to dete rm ine if it is bent. R eplace if
necessary.
Install or Connect
Pushrod. Make sure the pushrod seats properly in

the hydraulic lifter.
Important
When new rocker arms and/or balls are installed,
coat their bearing surfaces with Molykote or
equivalent.
3. Rocker arm nut.
ft
Adjust

VALVE ADJUSTMENT
1. Remove the rocker arm cover as outlined previously.
2. Crank the engine until the mark on the vibration
damper lines up with the O mark on the timing tab
and the engine in the number one firing position. This
may be determined by placing fingers on the number
SMALL BLOCK 6A4-7

20.
21.
22.
23.
24.
25.
Valve Keeper
Cap
Shield
O-Ring Seal
Seal
Damper
26.
27.
28.
29.
Spring
Intake Valve
R otator
Exhaust Valve
Figure 5 Valves and Components
3.
4.
5.
6.
one valve as the mark on the damper comes near the

O mark on the timing tab. If the rocker arms are not
moving, the engine is in the number one firing position.
If the rocker arms move as the mark comes up to the
timing tab, the engine is in the number six firing
position and should be turned over one more time to
reach the number one position.
With the engine in the number one firing position as
determ ined above, the follow ing valves may be
adjusted:
Exhaust: 1, 3, 4, 8
Intake: 1, 2, 5, 7
numbered cylinders are in the left bank, when viewed
from the rear of the engine).
Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all lash is
removed. This can be determined by rotating the
When the play has been removed, turn the adjusting
nut in one full additional turn (to center the lifter
plunger).
Crank the engine one revolution until the timing tab
O mark and vibration damper mark are again in
alignment. This is the number six firing position the
Exhaust: 2, 5, 6, 7
Intake: 3, 4, 6, 8
Install the rocker arm cover as outlined previously.
VALVE STEM SEAL AND

VALVE SPRING REPLACEMENT
1.
2.
3.
4.
Tools Required:
Spark plugs.
Valve keepers (20).

Apply compressed air to hold the valves in place.
Install a rocker arm nut (figure 6).
(figure 6).
J-5892-B.
5. Cap (21) and/or rotator (28), shield (22) and spring (26)
with damper (25).
6. O-ring seal (23).
7. Seal (24) (intake valve only).

Tools Required:
J-23590 Air Adapter
J-5892-B Spring Compressor
J-23738-A Vacuum Pump
1. New seal (24) (intake valve only). Install the seal over
the valve stem and seat it against the head.
2. Spring (26) with damper (25), shield (22) and cap (21)
and/or rotator (28).
6A4-8 SMALL BLOCK

INTAKE MANIFOLD
REPLACEMENT
3.
4.
5.
7.
14.
Figure 7Testing the Valve Seals

3. New O-ring seal (23) and valve keepers (20).
(figure 6).
Lubricate the O-ring seal with engine oil. Install
the seal on the valve stem. Make sure the seal is
not twisted.
15.
16.
17.
18.
Clean
Old gasket and RTV from the block, heads, and
intake manifold. Remove all RTV that is loose or will
cause interference at assembly.
Excessive carbon deposits from the exhaust and
EGR passages.
passages.

them in place.
Carefully release spring pressure. Make sure the
valve keepers stay in place.
Check each O-ring seal for leakage (figure 7).
Connect J-23738-A to the suction cup and
apply a vacuum. Watch the vacuum pump
gage. No air should be able to leak past
the seal. If the seal will not hold a vacuum,
it may have been damaged or improperly
installed.
4. Spark plugs.
5. Rocker arms, as outlined previously.
ft
Adjust

Air cleaner.
AIR crossover hose (G m odels with TBI engines).
Heater hose and upper radiator hose at the intake
manifold.
Generator bracket at the manifold.
Vacuum hoses at the m anifold, carburetor or TBI
unit, and EGR valve.
E le c tr ic a l c o n n e c tio n s a t th e m a n ifo ld and
carburetor or TBI unit.
Fuel line(s) at the carburetor or TBI unit.
Accelerator, cruise control, and TVS cables, as
equipped.
Air conditioning compressor and bracket and lay
aside (if equipped) (except G m odels with TBI
engines).
Brake booster vacuum pipe.
Components as follows on TBI engines:
Coil wires.
Emission control sensors and bracket on right side.
Cruise control trandsucer and bracket.
Fuel line bracket at rear of manifold. Move the
fuel lines aside.
Bracket at rear of belt idler (G models).
Carburetor or TBI unit (if necessary).
Intake manifold.
Gaskets and clips (some TBI engines).
L*
Inspect

1. Gaskets to the cylinder head' On TBI engines so
equipped, also install the clips over the gaskets to
the rib between the intake port^. Then apply a dot of
RTV to the upper side of the clip.
2. RTV to the front and rear sealing surfaces on the
block (figure 8). Apply a 5 mm (3/ie-inch) bead of
RTV (part number 1052366 or equivalent) to the
front and rear of the block as shown. Extend the
bead 13 mm (1/2-inch) up each cylinder head to seal
and retain the gaskets.
3. Intake manifold to the engine.
SMALL BLOCK 6A4-9
C. Forw ard
D. RTV S ealant
B-07915

Tighten
Intake manifold bolts to 48 N-m (35 ft. lbs.).
Use the tightening sequence shown in figure
9.
Carburetor or TBI unit (if removed).
Components as follows on TBI engines:
Bracket at rear of belt idler (G models).
Fuel line bracket at rear of manifold.
Cruise control transducer and bracket.
E m ission c o n tro l se n so rs and brackets.
Coil wires.
Brake booster vacuum pipe.
Air conditioning compressor and bracket (if removed).
10. Accelerator, cruise control, and TVS cables, as

equipped.
11. Fuel line(s) at the TBI unit or carburetor.
12. Electrical connections.
13. Vacuum hoses.
14. Generator bracket.
15. Heater hose and upper radiator hose.
16. AIR crossover hose (G models with TBI engines).
17. Air cleaner.
18. E ng in e cove r (G m odels).

Fill the cooling system with the proper quantity and
grade of coolant.
HYDRAULIC LIFTER
REPLACEMENT
B-09569
Figure 9Intake Manifold Bolt Tightening Sequence
Tools Required:
J-3049 Hydraulic Lifter Remover (Plier Type) or
J-9290-01 H ydraulic Lifter Remover (Slide
Hammer Type)
Rocker arm cover, intake manifold, and pushrod, as
place them in an organizer rack. The lifters must
be installed in the same bore from which they
were removed.
6A4-10 SMALL BLOCK
Figure 10Removing the Hydraulic Lifter

A stuck hydraulic lifter can be removed using
J-3049 (figure 10) or J-9290-01 (figure 11).
L * Inspect
Hydraulic lifter body for scuffing and scoring. If the
lifter body wall is worn or damaged, the mating bore
in the block should also be checked.
Check the fit of each hydraulic lifter in its mating
bore in the block. If the clearance is excessive, try a
new lifter.
The hydraulic lifter foot must be smooth and slightly
convex. If worn, pitted, or damaged, the mating

R efer to the p ro p e r u n it rep air m anual.
Install or Connect
1. Hydraulic lifters to the block. Lubricate the lifter foot
and body with Engine Oil Supplement or equivalent.
Im portant
When any new hydrau lic lifte rs or a new
camshaft is installed, change the engine oil and
filter. Engine Oil Supplement (or equivalent)
should be added to the crankcase oil.
R eplace all h y d ra u lic lifte rs when a new
2. Intake Manifold, as outlined previously.
A djust

ROCKER ARM STUD

REPLACEMENT
Tool Required:
J-5802-01 Rocker Arm Stud Remover
previously.
2. Rocker arm stud.
-- Install or Connect (Figures 13 and 14)

Tools Required:
J-5715 Reamer (0-003-inch oversize) or
J-6036 Reamer (0.013-inch oversize)
J-6880 Rocker Arm Stud Installer
rocker arm stud without reaming stud hole as
this could damage the cylinder head.
Figure 11Removing the Hydraulic Lifter (Typical)
Ream the hole to the proper size for the replacement

oversize rocker arm stud. Use J-5715 for 0.003-inch
oversize studs; J-6036 for 0.013-inch oversize studs
(figure 13).
SMALL BLOCK 6A4-11

EXHAUST MANIFOLD
REPLACEMENT
Figure 13Reaming the Rocker Arm Stud Bore

(Typical)
Coat lower end (press-fit area) of rocker arm stud with
hypoid axle lubricant.
installed to proper depth when the tool bottoms on the
cylinder head.
8.
9.
10.
Adjust
11.

Exhaust pipe at the manifold.
Lower the vehicle.
Oxygen sensor wire (if used) (left side manifold). Do
not remove the oxygen sensor unless replacement is
required.
AIR hose at the check valve.
Heat stove pipe (right side manifold).
Components as follows on R and V models:
Air conditioning compressor rear bracket at the
manifold (left side manifold).
Diverter valve and bracket (right side manifold).
Components as follows on G models with TBI engines:
Power ste e rin g pum p rear bracket at the
Dipstick tube bracket (right side manifold).
AIR pipe bracket at the manifold stud (carbureted
engines left side manifold).
Exhaust manifold bolts, washers, tab washers and
spark plug heat shields, as equipped.
Cast m anifolds are retained by bolts, tab
washers, and plain washers. Remove the outside
bolts first, then the center bolts.
Tubular (stainless steel) manifolds are retained
by bolts and plain washers.
Exhaust manifold.
Clean
Mating surfaces on the manifold and head.
Exhaust manifold to the cylinder head.
Exhaust manifold fasteners and spark plug heat
shields (where used).
Cast manifolds: Install the flat washers against
the manifold, then the tab washers and bolts.
Tighten
Two center bolts to 36 N m (26 ft. lbs.).
Outside bolts to 28 N m (20 ft. lbs.).
Bend the tab washers against the bolt
heads.
Tubular (stainless steel) manifolds: Install the
bolts and flat washers.
Tighten
3. Components as follows on G models with TBI engines:
Power ste ering pum p rear bracket at the
Dipstick tube bracket (right side manifold).
4. Components as follows on R and V models:
Air conditioning compressor rear bracket at the
Diverter valve and bracket (right side manifold).
6A4-12 SMALL BLOCK

5. AIR bracket at the manifold (carbureted engines left
side manifold).
6. Heat stove pipe (right side manifold).
8. Oxygen sensor wire (if used).
9. Exhaust pipe.
Lower the vehicle.
10. Engine cover.
0 0 0 0 0 0 0 0 .
CYLINDER HEAD
REPLACEMENT
++


3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.
15.
B-09572

Exhaust m anifold, as outlined previously.
Ground strap at rear of cylinder head (right side
cylinder head).
Components as follows for right side cylinder head
on R and V models:
AIR pipe at the rear of the cylinder head.
Spark plug wires from the support brackets.
Generator, and lay aside.
Components as follows for left side cylinder head on R
and V models:
Air conditioning compressor and front bracket (if
equipped) and lay aside.
Power steering pump, and lay aside.
Coolant sensor wire.
Spark plug wires from the support brackets.
Components as follows for right side cylinder head on
G models with TBI engines:
AIR pump bolt and spacer at the cylinder head.
N ut and s tu d a tta c h in g a ir c o n d itio n in g
compressor to cylinder head.
Fuel pipe, plug wire and wiring harness brackets
at the rear of the cylinder head.
Components as follows for left side cylinder head on G
models with TBI engines:
Nut and stud attaching main accessory bracket
to the cylinder head. It may be necessary to
loosen the remaining bolts and studs and move
the bracket forward slightly for clearance to
remove the cylinder head.
Cruise control transducer and spark plug wire
brackets at the rear of the cylinder head.
Components as follows on carbureted engines:
Generator, and lay aside (right side cylinder
head).
Air conditioning compressor and bracket, and lay
aside (left side cylinder head).
Spark plugs.
Cylinder head.
16. Head gasket.

13 1
Clean
Carbon deposits from com bustion chambers.

block.
C ylinder head bolt threads and threads in the block.
L*
Inspect


1. Head gasket.
even.
gaskets.
the bead up.
2. Cylinder head. Carefully guide the cylinder head ino
SMALL BLOCK 6A4-13
9.
10.

11.
Tighten
sequence shown in figure 15. Proper torque is
90 N m (65 ft. lbs.).
Adjust
6. Spark plugs.
7. Components as follows for right side cylinder head on
R and V models:
Spark plug wires to the support brackets.
Generator.
8. Components as follows for left side cylinder head on R
and V models:
12.
13.
14.
15.
16.
Air conditioning compressor and front bracket (if

equipped).
Spark plug wires to the support brackets.
Components as follows for right side cylinder head on
G models with TBI engines:
AIR pump bolt and spacer at the cylinder head.
Nut and stud attaching the air conditioning
compressor to the cylinder head.
Fuel pipe, plug wire and wiring harness brackets
at the rear of the cylinder head.
Components as follows for left side cylinder head on G
models with TBI engines:
Nut and stud attaching main accessory bracket
to the cylinder head.
Remaining main accessory bracket bolts and
nuts, if necessary.
Cruise control transducer and spark plug wire
brackets at the rear of the cylinder head.
Components as follows on carbureted engines:
Generator (right side cylinder head).
Air conditioning compressor and bracket (left
side cylinder head).
Ground strap at the rear of the cylinder head (right side
cylinder head).
Exhaust manifold, as outlined previously.
grade of coolant.

FRONT CRANKSHAFT SEAL
REPLACEMENT
0
1.
2.
3.
4.
5.
6.
7.

Tool Required:
J-23523-E Torsional Damper Puller and Installer
Torsional damper bolt.
Front crankshaft seal. Pry out with a large screwdriver.
Take care not to distort the timing cover.
Crankshaft key, if necessary.
Oil seal contact area on the torsional dam per shaft

for grooving and roughness. Replace if necessary.

Tools Required:
J-35468 Seal Installer
J-23523-E Torsional Damper Puller and Installer
6A4-14 SMALL BLOCK

NOTICE: The in e rtia w eig h t section o f the
procedures (w ith the p rop er tool) m ust be
followed or m ovem ent o f the inertia weight
section of the hub will destroy the tuning of the
torsional damper.
3. Stud (item A, figure 18) to the crankshaft. Thread
4. Torsional damper over the end of the stud. Align
keyway in the torsional dam per shaft with
crankshaft key.
5. Bearing, washer and nut (figure 18).
Turn the nut to pull the vibration damper
place.
Remove the tool.
Use a small amount of RTV sealant to seal
torsional damper key to crankshaft joint.
the
the
the
into
Tighten
the
Front cover to block bolts to 11.3 N m (100 in.

lbs.).
5. Water pump. Refer to ENGINE COOLING (SEC. 6B1).
Tighten

OIL PAN REPLACEMENT

A one piece type oil pan gasket is used.

1.
2.
3.
4.
5.
6.
7.
131

Water pump.
Oil pan, as outlined later.
Front cover bolts.
Front cover.
Front cover to block gasket.
Front crankshaft seal from the front cover. Pry out
cover.
Clean
Old gasket from the front cover and block.
Inspect
necessary.

Tools Required:
2. Front cover gasket to the front cover. Use gasket
cement to hold it in place.
3. Front cover to the engine.
1.
2.
3.
4.

Exhaust crossover pipe.
Flywheel/torque converter cover.
Strut rods at the engine mountings (V models with
automatic transmissions).
6. Oil pan and gasket.
jQ * Clean
y ] Inspect
Oil pan gasket for damage. Replace if necessary.
+ + I Install or Connect (Figure 20)

Apply sealant (GM part number 1052080 or equivalent)
to the front cover to block joint and to the rear
crankshaft seal to block joint. Apply the sealant for
about 25 mm (1 inch) in both directions from each of
the four corners.
1. Oil pan gasket to the oil pan.
2. Oil pan to the engine.
Oil pan bolts to 11.3 N m (100 in. lbs.).

Oil pan nuts to 22.6 N m (200 in. lbs.).
SMALL BLOCK 6A4-15

4. Strut rods at the engine mount (V m odels with
automatic transmissions).
5. Flywheel/torque converter cover.
6. Exhaust crossover pipe.
Lower the vehicle.

2. Nuts (73) (if equipped).
3. Bolt (72).
4. Oil pump (70) and buffle (71) (if equipped).
L*
Inspect
Oil pump pickup tube for looseness. If the tube is

loose in the oil pump body, replace it, as outlined in
the proper unit repair manual. A loose pickup tube
can result in an air leak and loss of oil pressure.
Oil Pump Repair

73
74

1. Oil pump to the engine. Align the slot in the oil pump
shaft with the tang on the distributor shaft. The oil
pump should slide easily into place. No gasket is used.
2. Baffle (71) (if equipped) and bolt (72).
Tighten
Bolt (72) to 90 N m (65 ft. lbs.).
3. Nuts (73) (if equipped).
Nuts (73) to 34 N-m (25 ft. lbs.).

4. O il pan, as o u tlin e d previously.
REAR CRANKSHAFT OIL SEAL

REPLACEMENT
++
1. Transmission.
70.
71.
72.
73.
74.
75.
NOTICE: Care should be taken when removing

the rear crankshaft oil seal so as not to nick the
crankshaft sealing surface.
Oil Pump
Baffle (Some 5.7L Engines)
Bolt
Nut (Some 5.7L Engines)
Gasket
Reinforcement
B-07916

out (figure 21). Take care not to damage the crankshaft
seal surface.
Inspect
Figure 20Oil Pan
Chamfer on crankshaft for grit, loose rust, and burrs.

Correct as necessary.
6A4-16 SMALL BLOCK

A.
80.
81.
82.
83.
84.
Rear o f B lock
Screw
Nut
R etainer
Stud
Gasket
83
F-02922
Figure 23Rear Crankshaft Oil Seal Retainer

Clean
Seal running surface on the crankshaft with a
non-abrasive cleaner.

Tool Required:
1. Rear crankshaft oil seal (figure 22).
Lubricate the inner and outer diameter of the
seal with engine oil.
Install the seal on J-35621.
Position J-35621 against the crankshaft. Thread
the attaching screws into the tapped holes in the
crankshaft.
Tighten the screws securely with a screwdriver.
This will ensure that the seal is installed squarely
over the crankshaft.
Turn the handle until it bottoms.
Remove J-35621.
3. Transmission.

RETAINER REPLACEMENT
Remove or Disconnect (Figures 21 and 23).
1. Transmission.
6. Gasket (84).
out (figure 21).
] Clean
Gasket surfaces on block and seal retainer.

Whenever the seal retainer is removed, a new retainer
gasket and rear crankshaft oil seal must be installed.
1. Gasket (84) to the block. It is not necessary to use
sealant to hold the gasket in place.
Tighten
Screws (80) and nuts (81) to 15.3 N m (135 in.
lbs.).
5. Rear crankshaft oil seal as outlined previously.
7. Transmission.
SMALL BLOCK 6A4-17
A. Align Marks as Shown
B-05289
Figure 25Timing Marks
MEASURING CHAMSHAFT
LOBE LIFT
1.
2.
3.
4.
Tool Required:
J-8520 Camshaft Lobe Lift Indicator
Remove the rocker arm as outlined previously.
Refer to figure 24. Position the dial indicator (part of
Rotate the crankshaft slowly in the direction of normal
rotation until the lifter is on the heel of the cam lobe. At
this point, the pushrod will be in its lowest position.
Set dial indicator on zero, then rotate the crankshaft
bump the engine dver, until the pushrod is in fully
raised position.
Important
Whenever the engine is cranked remotely at
the starter, with a special jum per cable or
other means, the distributor prim ary lead or
coil primary leads should be disconnected.
5. Compare the total lift recorded from the dial indicator
with specifications.
6. If c a m sh a ft rea d in g s fo r all lobes are w ith in
7. Install the rocker arm and adjust the valves as
++
1.
2.
3.
4.
5.

27)
Tool Required:
J-5825-A Crankshaft Sprocket Puller
Air cleaner.
Grille (G models).
Air conditioning condensor from its mounting and
swing it forward (G models).
6A4-18 SMALL BLOCK

Install two or three 5/ie18 bolts 100-125 mm
(4-5 inches) long into the camshaft threaded
holes. Use these bolts to handle the camshaft
(figure 27).
Cleaning Inspection and Repair

manual.
The unit re p air m anual also d escrib e s ca m sh aft
Install or Connect (Figures 25 through 27 and

35 through 38)
1.
2.
3.
Tool Required:
J-5590 Crankshaft Sprocket Installer
q u a lity e ngine oil s u p p le m e n t (GM Engine Oil
Two or three 5/ie18 bolts 100-125 mm (4-5 inches)
long into the camshaft threaded holes. Use these bolts
to handle the camshaft.
Cam shaft to the engine (figure 27). Handle the
bearings.
Lower the engine.
Engine mount through-bolts.
NOTICE: See
section.
6. Fan, shroud, and radiator. Refer to ENGINE COOLING
(SEC. 6B).
8. Water pump. Refer to ENGINE COOLING (SEC. 6B).
10. Front cover, as outlined previously.
Tighten
T h ro u g h -b o lts to s p e c ific a tio n s . R efer to

figures 35 through 38.
4. Crankshaft sprocket (if removed). Use J-5590 (figure
26). Make sure the timing mark faces outside.
Im portant

13. Pushrods and hydraulic lifters, as outlined previously.
14. Fuel pump and pushrod (carbureted engines).

Tighten

16. Camshaft sprocket and timing chain. The sprocket is a

Fuel pump and pushrod (carbureted engines).
17. Crankshaft sprocket (if required). Use J-5825 (figure

26).
Im portant
R eplace all h y d ra u lic lifte rs, ch an ge the
engine oil and filter, and add GM Engine Oil
Supplem ent (or equivalent) to the engine oil
whenever a new cam shaft is installed.
18. Front engine mounting through bolts.

the oil pum p screen, jacking against the oil
pany may cause it to be bent against the pump
Raise the engine.
19. Camshaft
N o tice on page 6A4-1 of this
ft
A djust

13. Water pump. Refer to ENGINE COOLING (SEC. 6B).
SMALL BLOCK 6A4-19

15. Fan, shroud, and radiator. Refer to ENGINE COOLING
(SEC. 6B).
16. Air conditioning condensor (G models).
17. Grille (G models).
18. Air cleaner.
grade of coolant.
CONNECTING ROD AND

PISTON REPLACEMENT
++
1.
2.
3.
4.
5.
6.
7.

Tool Required:
J-5239 Guide Set
Cylinder head, as outlined previously.
bores.
reamer.
cap for identification marks. Mark the parts if required.
The connecting rod and cap must be kept together as
mating parts.
Attach J-5239 to the connecting rod bolts (figure
28).
Connecting rod bearing.
C leaning, In sp e ctio n , and R epair

unit repair manual.
Piston rings.
Cylinder bores.
Install the bearings in the connecting rod and

connecting rod cap.
2. Piston and connecting rod to the proper bore.
figure 29. Lubricate the piston and rings.
Without disturbing the ring end gap location,
O
^ 2
ENGINE LEFT
ENGINE FRONT
ENGINE RIGHT
c

Tools Required:
J-5239 Connecting Rod Guide Set
J-8037 Ring Compressor
Make sure the cylinder walls are clean. Lubricate the
cylinder wall lightly with engine oil.
Make sure the piston is installed in the matching
cylinder.
Connecting rod bearings.
Be certain that the bearings are of the proper
size.
A.
B.
C
D.
Oil Ring Rail Gaps

2nd Compression Ring Gap
Notch In Piston
Oil Ring Spacer Gap
(Tang In Hole Or Slot W ith Arc)
E. Top Compression Ring Gap
B-07895
Figure 29Piston Ring End Gap Locations
6A4-20 SMALL BLOCK
A. Valve Disc
93. O il F ilte r Bypass Valve
94. B olt
B-05286
Figure 32Oil Filter Bypass Valve

m arked, begin nin g at the fro n t of the engine.
Cylinders 1, 3, 5 and 7 are the left bank and, 2, 4, 6,
and 8 are the right bank. The numbers on the
connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If a
connecting rod is ever transposed from one block or
cylinder to another, new connecting rod bearings
should be fitted and the connecting rod should be
num bered to correspond w ith the new cylinder
number.
The piston must be installed so that the notch in
the piston faces the front of the engine (figure
29).
Place the piston in its matching bore. The
connecting rod bearing tang slots must be on the
side opposite the camshaft. Using light blows
with a hammer handle, tap the piston down into
its bore (figure 30). At the same time, from
beneath the vehicle guide the connecting rod to
the crankpin with J-5239 (figure 28). Hold the
ring compressor against the block until all rings
have entered the cylinder bore.
Measure
Connecting rod bearing clearance. Refer to
the proper unit repair manual.
Connecting rod cap nuts to 60 N m (45 ft. lbs.).
Measure
gage between the connecting rods (figure 31).
The correct clearance is 0.006-0.014-inch.
Im portant
Each connecting rod and bearing cap should be
Tighten

++
Rempve or Disconnect (Figure 32)
1. Oil filter.
L*
Inspect
Bypass valve spring and valve disc for proper

operation, cracks, and dam age. If replacement
is needed, the oil filter bypass valve (93) must
be replaced, as follows:
2. Bolts (94).
3. Oil filter bypass valve.
SMALL BLOCK 6A4-21
Figure 33Removing the Main Bearing Insert

Main bearing cap replacement (shimming procedure).
jjJJ| Clean
Valve cham ber in the block.

1. Oil filter bypass valve (93).
2. Bolts (94).
Bolts (94) to 26 N-m (20 ft. lbs.).

3. Oil filter.
4. Engine oil, as needed.
MAIN BEARING
REPLACEMENT
i l l Remove or Disconnect (Figure 33)
1.
2.
3.
4.
5.
6.
Tool Required:
J-8080 Main Bearing Remover/Installer
Spark plugs.
Main bearing caps.
markings. Mark the caps if necessary. The caps
must be returned to their original locations
during assembly.
caps.
Insert J-8080 into the crankshaft oil hole (figure
33).
Rotate the crankshaft to "turn the bearing insert
out of the block.
Cleaning, Inspection, and Repair

unit repair manual contains information on
Crankshaft.
-H" Install or Connect (Figures 33 and 34)

Tool Required:
Insert tool J-8080 into a crankshaft main bearing
oil hole (figure 33).
Insert the plain end (without the bearing tang) of
the insert between the crankshaft and the
Rotate the crankshaft to roll the insert into the
block.
Remove the tool.
2. Lower main bearing inserts to the main bearing caps.
Measure
Main bearing clearance. Refer to the proper
unit repair manual. If the engine is in the
vehicle, the crankshaft must be supported
upward to remove any clearance from the
upper bearing. The total clearance can then
be measured between the lower bearing and
journal.
block.
Tighten
Main bearing cap bolts to specifications.
Outer bolts on #2, #3, and #4 main bearing
caps: 95 N m (70 ft. lbs.).
All others: 110 N m (80 ft. lbs.).
4. Rear main bearing cap and bolts.
Rear main bearing cap bolts tem porarily to 14

N-m (10 ft. lbs.).
6A4-22 SMALL BLOCK

Measure
then forward with a lead hammer. This will
lin e up th e re a r m ain b e a rin g and
crankshaft thrust surfaces.
Tighten the rear main bearing cap bolts to
110 N m (80 ft. lbs.).
W ith the c ra n k s h a ft fo rce d fo rw a rd ,
bearing with a feeler gage (figure 34). The
proper clearance is 0.002-0.006-inch.
If correct end play cannot be obtained, be
certain that the correct size rear main
bearing has been installed. Production
engines may have rear main bearings that
are 0.008-inch wider across the thrust
faces than standard. Refer to the proper
unit repair manual for more information.
8 . Oil pump, as outlined previously.

10. Spark plugs.
a
B
1. Transmission, flywheel housing, and clutch.

2. Flywheel bolts.
3. Flywheel.

any burrs.

Replace the flywheel if necessary. Do not machine
the flywheel.


this will changemetal structure.
2. Uniformly heat the flywheel gear to temperature which
will expand the gear to permit installation. Temperature
must not exceed 204C (400F).
flywheel.
Install or Connect
1. Flywheel.
2. Flywheel bolts.
T ig h te n

ENGINE MOUNTINGS
Broken or deterioratedmountings can

mounting breakage occurs, the remaining
stresses.
NOTICE:

F ro n t Engine M o u n tin g s
Whenraisingor supporting theengine

for anyreason, donot useajack under the oil
pan, anysheet metal or crankshaft pulley. Due
to thesmall clearance between theoil panand
theoil pumpscreen, jackingagainst theoil pan
may cause it to be bent against the pump
screen, resulting in adamagedoil pickup unit.
NOTICE:
1. Raise the engine to remove weight from the mountings

and to place a slight tension on the rubber cushion.
Observe both mountings while raising the engine.
cracks.
of the mounting.
and tighten the bolts or nuts attaching the mounting to
the engine, frame, or bracket.
Rear M o u n tin g s
Observe the transmission mounting.
of the mounting.
Mounting bottomed out (tailshaft can be moved
up but not down).
3. If there is relative movement between a metal plate of
the mounting and its attaching point, tighten the bolts
or nuts attaching the mounting to the transmission or
crossmember.
SMALL BLOCK 6A4-23

NOTICE: Whenraisingor supporting theengine

for anyreason, do not useajack under the oil
to the small clearance between the oil panand

between the rear of the engine and the dash
panel which could cause distributor housing
damage.
Raise the engine only enough to permit removal of the
engine mounting.

NOTICE: See Notice on page 6A4-1 of this

section.
Tighten
through 38.
3. Engine mount through-bolt and nut lower the engine
until the bolt can be inserted. Install the nut.
-a
B
1. Mounting.

section.

through 42.
REAR MOUNTING REPLACEMENT (P MODELS

WITH FLYWHEEL HOUSING MOUNTING)
1. Bolt, cushion, and spacer.

to the small clearance between theoil panand
2. Engine mounting.

1. Engine mounting. Align the hole in the mounting with
the hole in the crossmember.

Lower the engine.

section.
2. Spacer, cushion, and bolt.
Through-bolt nut to specifications. Refer to

figures 35 through 38.
REAR MOUNTING REPLACEMENT (EXCEPT

P-MODELS WITH FLYWHEEL HOUSING MOUNTING)

to thesmall clearance between the oil panand
Support the rear of the engine to relieve the weight on
the rear mountings.
3. Mounting.
Tighten
ENGINE REPLACEMENT
R AND V MODELS
2. Hood.
3. Air cleaner.
4. All accessory drive belts.
5. Fan and water pump pulley.
6 . Radiator and shroud. Refer to RADIATOR (SEC.
6B2).
8 . Accelerator, cruise control, and detent linkage (if
used) from carburetor.
9. Air conditioning compressor (if used) and lay aside.
10. Power steering pump (if used) and lay aside.
11. Engine wiring harness from the engine.
6A4-24 SMALL BLOCK
A. Forward
B. 40 N m (30 Ft. Lbs.)
C. Torque B olt To 115 N-m (85 Ft. Lbs.) Or, Torque Nut
To 75 N-m (55 Ft. Lbs.)
D. 48 N-m (36 Ft. Lbs.)
E. Torque B olt To 48 N-m (36 Ft. Lbs.) Or, Torque Nut To 40 N-m (30 Ft. Lbs.)
B-07621
Figure 35Front Engine Mounting (R Models)
SMALL BLOCK 6A4-25
152
A. 40 N m (30 ft. lbs.)

B. Torque bo lt to 115 N m (85 ft. lbs.) Or,
Torque nut to 75 N m (55 ft. lbs.).
C. 48 N-m (36 ft. lbs.).
D. 65 N-m (48 ft. lbs.).
E. Forward
152. Transm ission S truck Bracket (A utom atic Transm ission)
O r S pacer (Manual Transm ission)
Figure 36Front Engine Mounting (V Models)
B-07622
6A4-26 SMALL BLOCK
B. Torque B olt To 100 N m (75 Ft. L b s .) Or, Torque N ut To 48 N m (36

C. 48 N m (36 Ft. Lbs.)
D. Torque B olt To 52 N m (38 Ft. Lbs.) Or, Torque Nut To 40 N-m (30 Ft. Lbs.)
E. Torque B olt O r N ut to 40 N-m (30 Ft. Lbs.)
150. Spacer OR Power Steering Pump Bracket (Left Side Only)
B-07919
Figure 37Front Engine Mounting (G Models)

Tighten
12. Fuel lines.

13. Vacuum lines from the intake manifold.
Raise the vehicle. Support with suitable safety
stands.

and 36.
16. Flywheel or torque converter underpan.
3. Bell housing to engine bolts. Remove the transmission

support.
5. Fuel gage wiring.
6 . Starter.
17. W iring along oil pan rail.
8 . Flywheel or torque converter underpan.
18. Starter.
9. Strut rods at the engine mountings (V models with

Drain the crankcase oil.

14. Exhaust pipes from the manifolds.
15. Strut rods at the engine m ountings (V models with
19. W iring for fuel gage.

Lower the vehicle.
10. Exhaust pipes to the manifolds.

Lower the vehicle.
Support the transm ission.
11. Vacuum lines to the intake manifold.
Attach a suitable lifting fixture.
12. Fuel line.
13. Engine wiring harness.
22. Front engine m ounting to frame bolts.
14. Power steering pump (if used).
23. Engine.
15. Air conditioning compressor (if used).
16. Accelerator, cruise control, and detent linkages.

17. Heater hoses.
1 . Engine to the vehicle.
18. Radiator and shroud. Refer to RADIATOR (SEC. 6B2).

stands.
20. Air cleaner.

section.
2. Front engine mounting to frame bolts.

21. Hood.
oil.
SMALL BLOCK 6A4-27
A. F ro n t
B. 100 N m (75 Ft. Lbs.)

C. 48 N m (36 Ft. Lbs.)
D. 40 N m (30 Ft. Lbs.)
MODELS WITHOUT I-BEAM AXLE
MODELS WITH I-BEAM AXLE (RP0-FS3)

B-07920
Figure 38Front Engine Mounting (P Models)

G MODELS
1.
2.
3.
4.
5.

Coolant reservoir bottle.
Grille and lower grille valance.
A ir c o n d itio n in g c o n d e n s o r. R e fe r to AIR
CONDITIONING (SEC. 1 B).
6 . Radiator. Refer to RADIATOR (6B2).
7. Power steering pump, and lay aside.
8 . Engine cover.
9. Air cleaner.
10. Carburetor or TBI unit.
11. Engine wiring harness from the conductor on the
dash panel.
12. Vacuum hoses and electrical wiring, as required.
14. Therm ostat housing.
15. Oil filler tube.
16. Cruise control servo, bracket, and transducer (if

equipped).
stands.
17. Exhaust pipes at the exhaust manifolds.
18. P ro p e lle r s h a ft at the tra n s m is s io n . P lug the
transm ission end.
19. Transmission shift linkage and speedometer cable.
20. Fuel and vapor return hoses at the engine.
21. Rear engine m ounting bolts.

to thesmall clearancebetween the oil panand
Support the engine with a suitable jack.
22. Front engine mounting bracket to frame bolts and nuts.
6A4-28 SMALL BLOCK
ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPQ-M40)
MODELS WITH THM 400 TRANSMISSION (RPO-M4Q)

A. Forward
B. 48 N m (36 Ft. Lbs.)
B-07921
Figure 39Rear Engine Mounting (R Models)
SMALL BLOCK 6A4-29

24. Front engine mounting frame brackets. Raise the
engine slightly to allow removal of the mounting
bracket. Block the engine in place with wood blocks.
Lower the vehicle.
Install a suitable lifting fixture.
25. Engine and transmission from the vehicle.

pan, any sheet metal or crankshaft pulley. Due
to thesmall clearancebetween theoil panand
Support the engine with a suitable jack.

section.
2. Engine m ounting frame brackets.
A. 54 N m (40 Ft. Lbs.)
B. 48 N m (36 Ft. Lbs.)
C. F orw ard
Raise the engine slightly and position the

brackets against the engine mountings.
Install the through-bolts finger tight.
Lower the engine.
Install the mounting bracket to frame bolts and
nuts.
B
B-07897
F igure 40 Rear Engine M o u n tin g (V M odels)

E n g in e
m o u n tin g
fa s te n e rs
specifications. Refer to figure 37.
Remove the jack.
3. Rear engine mounting bolts.
to
Tighten
4.
5.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20 .
21 .
22.
Engine m ounting to transmission bolts to 48

N-m (36 ft. lbs.).
Fuel and vapor return lines.
Transmission shift linkage and speedometer cable.
Propeller shaft.
Exhaust pipes.
Lower the vehicle.
Cruise control servo, bracket, and transducer (if
equipped).
Oil filler tube.
Thermostat housing.
Heater hoses.
Vacuum hoses and electrical wiring.
Engine wiring harness connector.
Carburetor or TBI unit.
Air cleaner.
Air conditioning condensor (if equipped). Refer to AIR
CONDITIONING (SEC. 1 B).
Grille and lower grille valance.
Coolant reservoir bottle.
6A4-30 SMALL BLOCK
Figure 42Rear Engine Mounting (P Models with Transmission Tail Type Mounting)
SMALL BLOCK 6A4-31
B-07899
Figure 43Rear Engine Mounting (P Models

with Flywheel Housing Type Mounting)
23. Proper quantities and grades of coolant and engine oil.
Refer to AIR CONDITIONING (SEC. 1 B).
6A4-32 SMALL BLOCK
SPECIFICATIONS
GENERAL DATA:
Type
Displacement
RPO (VIN Code)
Bore
Stroke
Compression Ratio
Firing Order
Oil Pressure
V6
5.0L (305 Cu. In.)
L03 (H)
L05 (K)
5.7L (350 Cu. In.)

LS9 (L)
LT9 (M)
4.00
3.736
3.480
19.3
8.3:1
1-8 -4 -3-6 -5 -7-2
10 psi @ 500 RPM; 30-55 psi @ 2000 RPM
CYLINDER BORE:
Diameter
Out Of
Round
3.7350-3.7385
3.9995-4.0025
0.001 (Maximum)
0.002 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.001 (Maximum)
Production
Service
Thrust Side
Relief Side
Taper
Service
PISTON:
Production
Service Limit
0.0007-0.0017
0.0027 (Maximum)
PISTON RING:
C
n
M
p
R
Groove
Production
Service Limit
s
o
Production
Gap
N
0
I
L
Groove
Clearance
Gap
0.0012-0.0032
2 nd
Clearance
S
I
Top
Hi Limit Production +0.001

Top
0 .010 -0.020
2 nd
0.010-0.025
Service Limit
Production
Service Limit
Production
Service Limit
0.002-0.007
0.015-0.055
Production
Service Limit
0.9269-0.9271
0.0002-0.0007
0.001 (Maximum)
PISTON PIN:
Diameter
Clearance
In Piston
Fit In Rod
*8.6:1 w ith RPO-NA4

9.3:1 w ith RPO-NA1
SMALL BLOCK 6A4-33
SPECIFICATIONS
DISPLACEMENT
CRANKSHAFT:
5.0L (305 Cu. In.)

#1
Diameter
Main
Journal
#2, #3, #4
#5
Production
Service Limit
Production
Service Limit
Taper
Out Of
Round
#1
Production
Main
Bearing
Clearance
#2, #3, #4
#5
#1
#2, #3, #4
#5
Service Limit
Crankshaft End Play

Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
Taper
Crankpin
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
5.7L (350 Cu. In.)
2.4484-2.4493
2.4481-2.4490
2.4479-2.4488
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
0.0008-0.0020
0.0011-0.0023
0.0017-0.0032
0.0010-0.0015
0.0010-0.0025
0.0025-0.0035
0.002-0.006
2.0988-2.0998
0.0005 (Maximum)
0.001 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.0013-0.0035
0.003 (Maximum)
0.006-0.014
CAMSHAFT:
Intake
Exhaust
Lobe
Lift + 0.002
Journal Diameter
Camshaft End Play
0.2336
0.2565
0.2565
0.2690
1.8682-1.8692
0.004-0.012
VALVE SYSTEM:
Hydraulic
1.50:1
Lifter
Rocker Arm Ratio
Stem
Clearance
Valve
Spring
(Outer)
Valve
Spring
Damper
Production
Service
Free Length
Pressure
lbs. @ in.
Face Angle (Intake & Exhaust)

Seat Runout (Intake & Exhaust
Seat Width

CT) cn
o o
Intake
Exhaust
Valve Lash
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Closed
Open
Installed Height
V32"
Free Length
Approx. # of Coils
0.002 (Maximum)
V32-V16
1/l 6-3/32
0.0010-0.0027
0.0010-0.0027
2.03
76-84 lbs. @ 1.70"
194-206 lbs. @ 1.25"
123/32
1.86
6A4-34 SMALL BLOCK
Item
N-m
Rocker Arm Cover Nuts (Carbureted Engines)......................................................... ........ 7.3
Rocker Arm Cover Bolts (TBI Engines)............................................................................... 11.3
Intake Manifold B o lts .............................................................................................................. 48
Exhaust Manifold B o lts .................................................................................................
Cast Manifolds:
Two Center B o lts:............................................................................... 36
All O thers:.................................................................................... ........ 28
Tubular (Stainless Steel) Manifolds (All B olts)........................................................... 36
C ylinder Head B o lts ........................................................................................................ ........ 90
Torsional Damper B o lt............................................................................................................ 95
Front Cover B o lts ............................................................................................................ ........ 11.3
Oil Pan Nuts at C orners................................................................................................. ........ 22.6
Oil Pan Bolts..................................................................................................................... ........ 11.3
Oil Pump B o lt................................................................................................................... ........ 90
Oil Pan Baffle Nuts (Some 5.7L Engines).................................................................. ........ 34
Rear Crankshaft Oil Seal Retainer Screws and N u t s ............................................ ........ 15.3
Camshaft Sprocket B o lts ............................................................................................... ........ 24
Connecting Rod Cap N uts..................................................................................................... 60
Oil Filter Bypass Valve B o lts ........................................................................................ ........ 26
Main Bearing Cap Bolts
Outer Bolts on #2, #3, and #4 C a p s .................................................................. ........ 95
All O th e r s ......................................................................................................................... 110
Oil Pump Cover Bolts . ............................................................................................... ........ 9.0
Flywheel B o lts ......................................................................................................................... 100
Spark P lu g s ..................................................................................................................... ........ 30
Water Outlet B o lts .......................................................................................................... ........ 28
Water Pump B o lts .......................................................................................................... ........ 40
Flywheel Housing B o lts ................................................................................................. ........ 44
Rocker Arm Cover Studs to Head (Carbureted Engines)................................................ 1.7
Oil Pan Studs to Back or Rear Oil Seal R e ta in e r........................................................... 1.7
Ft. Lbs.
35
26
20
26
65
70
65
25
18
45
20
70
80
75
22
21
30
32
In. Lbs.
65
100
100
200
100
135
80
15
15
SMALL BLOCK 6A4-35
SPECIAL TOOLS
1.
J-23523-E
2.
J-5892-B
3.
J-23590
4.
5.
6.
10.
J-3049
11
J-5802-01
12.
13.
J-5715
J-6036
14.
J-6880
15.
J-5825-A
16.
J-5590
17.
J-8520
18.
J-35621
J-35468
J-8080
J-8037
7.
J-5239
8.
J-23738-A
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
A \
o ^
J-9290-01
T orsion al D am pe r R em ove r and In s ta lle r

Valve S p rin g C o m p re s s o r
A ir A d a p te r
C ra n k s h a ft Seal In s ta lle r and C e n te rin g Tool
M ain B e aring R ep lace r
P isto n R ing C o m p re s s o r
G u id e Set
V a cuu m Pum p
H y d ra u lic L ifte r R em ove r (S lid e H a m m e r Type)
10.
11.
12.
13.
14.
15.
16.
17.
18.
H y d ra u lic L ifte r R em over (P lie r Type)

S tu d R em over
R eam er (0.003-inch oversize)
R eam er (0.013-inch oversize)
S tu d In s ta lle r
C ra n k s h a ft G ear P u lle r
C ra n k s h a ft G ear In s ta lle r
Dial In d ic a to r A d a p te r
R ear C ra n k s h a ft Seal In s ta lle r
F-02562
6A4-36 SMALL BLOCK
6A5-1
SECTION 6A5
7 .4 L IT E R V 8
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of
retention of this part.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ....................................................................................................................................................................................6 A 5 - 1

E ngine L u b ric a tio n ..................................................................................................................................................................6 A 5 - 1
O n-V ehicle S e r v ic e .................................................................................................................................................................... 6 A 5 - 3
R ocker A rm C over R e p la c e m e n t...................................................................................................................................... 6 A 5 - 3
R ocker A rm and P ushrod R e p la ce m e n t........................................................................................................................... 6 A 5 - 3
Valve A d ju s tm e n t.................................................................................................................................................................... 6 A 5 - 4
Valve Stem Seal and Valve S p rin g R e p la c e m e n t.........................................................................................................6 A 5 - 4
Intake JManifold R e p la c e m e n t............................................................................................................................................. 6 A 5 - 5
H yd ra u lic L ifte r R e p la c e m e n t............................................................................................................................................. 6 A 5 - 6
R ocke r Arm S tud R e p la c e m e n t.........................................................................................................................................6 A 5 - 7
E xhaust M anifold R e p la c e m e n t........................................................................................................................................ 6 A 5 - 7
C ylin d e r Head R e p la c e m e n t................................................................................................................................................6 A 5 - 7
T o rsio n a l D am per and F ro n t C ra nksh a ft Seal R e p la c e m e n t.................................................................................... 6 A 5 - 8
F ront C over R e p la c e m e n t.................................................................................................................................................... 6 A 5 - 9
Oil Pan R e p la c e m e n t............................................................................................................................................................. 6 A 5 -1 0
Oil Pum p R e p la c e m e n t.........................................................................................................................................................6A5-11
Rear C rankshaft Oil Seal R e p la c e m e n t........................................................................................................................... 6A5-11
M easuring C am shaft Lobe L i f t ................................................................................................................ ....................... 6 A 5 -1 3
C am shaft R e p la c e m e n t.........................................................................................................................................................6 A 5 -1 3
C o n ne cting Rod and P isto n R e p la ce m e n t.......................................................................................................................6 A 5 -1 5
Oil F ilte r Bypass V a lv e .........................................................................................................................................................6 A 5 -1 7
Main Bearing R e p la c e m e n t..................................................................................................................................................6 A 5 -1 7
C rankshaft R e p la c e m e n t...................................................................................................................................................... 6 A 5 -1 8
Flyw heel R e p la c e m e n t.........................................................................................................................................................6 A 5 -1 8
E ngine M o u n tin g s ..................................................................................................................................................................6 A 5 -1 9
Engine R e p la c e m e n t............................................................................................................................................................. 6 A 5 -2 2
S p e c ific a tio n s ............................................................................................................................................................................. 6 A 5 -2 7
S pecial T o o ls ............................................................................................................................................................................... 6 A 5 -3 0
DESCRIPTION
7.4L engines are 90-degree V 8 type, overhead valve,
ENGINE LUBRICATION
water cooled with cast iron block and heads.. .

mam bearings, with crankshaft thrust taken at the number
Lubrication schematics are shown in Figure 1. The gear

Qj|
drjven frQm th<j djstrjbutor shaft which is
geaf drjven frQm {he camshaft 0 i| js drawn jn t0 the oj|
five (rear) bearing.

and is chain driven. Motion from the camshaft is transmitted to the valves by hydraulic lifters, pushrods, and ball
pump through a pickup screen and pipe.

excessive oil pressure, a bypass valve is provided,
R|tered oj| f|ows jn t0 the majn ga|)ery and then t0 the
type rocker arms. The valve guides are integral in the cylinder head.
. . . .
The connecting rods are forged steel, with precision insert type crankpin bearings. The piston pins are a press fit

j h e timing chain is drip fed from the front camshaft
splash.
6A5-2 7.4 LITER V8
C y lin d e r w a lls are o ile d by o il th ro w n

o ff p ressure fed c o n n e c tin g rod bea rin gs.
CYLINDER WALL AND

CAMSHAFT LOBE OILING
OIL FILTER AND
DISTRIBUTOR OILING
FUEL PUMP PUSH

ROD OILING
CRANKCASE AND CRANKSHAFT OILING
VALVE MECHANISM OILING

B-09187
7.4 LITER V8 6A5-3
ON-VEHICLE SERVICE

2. Reinforcements, clips, and nuts.
Tighten

Air conditioning compressor rear brace (if removed).
Heat stove pipe (if removed).
Wiring harnesses and spark plug wire loom (TBI
engines).
7. Air cleaner.
8 . Battery negative cable.

REPLACEMENT
++

2. Rocker arm nut.
pushrod out.
4. Pushrod.
Important
ROCKER ARM COVER

REPLACEMENT
++

L*
Rocker arms and balls at their mating surfaces.

These surfaces should be smooth and free from
scoring or other damage.
Rocker arm areas which contact the valve stems
and the sockets which contact the pushrods. These
areas should be smooth and free of damage and
wear.
su rfa ce to dete rm ine if it is bent. R eplace if
necessary.

2. Air cleaner.
3. Crankcase ventilation hoses at the rocker arm cover.
4. W iring harnesses from the clips at the rocker arm
cover.
5. Spark plug wire clip from the bracket. Move the
spark plug wire loom out of the way (TBI engines).
6 . Heat stove pipe (right side rocker arm cover).
7. Air conditioning compressor rear brace (if equipped)

(left side rocker arm cover).
8 . Rocker arm cover nuts, reinforcements, and clips.
Inspect
++
Install or Connect
1. Pushrod. Make sure the pushrod seats properly in

the hydraulic lifter.
Clean
All traces of old gasket from the rocker arm cover
and cylinder head.
L * Inspect
Rocker arm cover sealing surface for distortion.
Im portant
W hen new rocker arm s a nd /or balls are
installed, coat their bearing surfaces with
Molykote or equivalent.
3. Rocker arm nut.
tP
Adjust

6A5-4 7.4 LITER V8

20. N u t
21. Ball
21
11'
23.
22
24.
23
S :
26
29
31.
32.
33.
R o c k e r A rm
R o c k e r A rm S tud
Valve K eepers
C ap
R o ta to r
S p rin g w ith D am per
E x h a u s t Valve
In ta ke Valve
P u sh ro d G u id e
Seal
33
B-00557
Figure 3Adjusting the Valves
VALVE ADJUSTMENT
2. Crank the engine until the mark on the vibration
dam per lines up with the O mark on the tim ing
tab and the e n g in e in the num ber one firin g
position. This may be determined by placing fingers
on the num ber one valve as the mark on the damper
comes near the O mark on the tim ing tab. If the
rocker arms are not moving, the engine is in the
number one firing position. If the rocker arms move
as the mark comes up to the tim ing tab, the engine
is in the num ber six firing position and should be
turned over one more tim e to reach the num ber one
position.
3. With the engine in the number one firing position as
determ ined above, the following valves may be
adjusted:
Exhaust: 1 , 3, 4, 8
Intake: 1 , 2, 5, 7
F-02374
Figure 4Cylinder Head and Components

5. Crank the engine one revolution until the tim ing tab
O mark and vibration dam per mark are again in
alignment. This is the num ber six firing position the
Exhaust: 2, 5, 6 , 7
Intake: 3, 4, 6 , 8
6 . Install the rocker arm cover as outlined previously.
VALVE STEM SEAL AND


num bered cylinders are in the left bank, when
viewed from the rear of the engine).
4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until ali lash
is removed. This can be determined by rotating the
W hen th e p la y has been rem ove d, tu rn th e
adjusting nut in three quarters (3/4) additional turn
(to center the lifter plunger).
1.
2.
3.
4.
Tools Required:
J-23590 Air Adapter
J-5892-B Spring Com pressor
Spark plugs.
Valve keepers.
7.4 LITER V8 6A5-5

Adjust
6 . Rocker arm covers, as outlined previously.
INTAKE MANIFOLD
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
F-02375
Figure 5Compressing the Valve Spring

Apply compressed air to hold the valves in
place.
(figure 5).
13.
14.
15.
16.
17.
18.
19.
20.

Air cleaner.
Upper radiator hose, and water pump bypass hose.
Heater hose and pipe (TBI engines) or heater hose
(carbureted engines).
Wire at sensor at front of intake m anifold (TBI
engines).
Accelerator, cruise control, and TVS cables, as
equipped.
W iring harness from clips.
Cruise control transducer (if equipped).
Fuel line at carburetor or fuel lines at TBI unit.
Vacuum hoses, as necessary.
Distributor. Refer to ENGINE ELECTRICAL (SEC.
6 D).
Wires at ignition coil (TBI engines).
EGR solenoid with bracket (TBI engines).
MAP sensor with bracket (TBI engines).
A ir c o n d itio n in g c o m p re s s o r re a r b ra c k e t (if
equipped).
Front generator/AIR pump bracket (TBI engines) or
upper generator bracket (carbureted engines).
Intake manifold.
Gaskets and seals.

J-5892-B.
5. Cap (25) and spring with dam per (23).
6 . Seal (24).

Tools Required:
J-23590 Air Adapter
J-5892-B Spring Compressor
1. New seal. Install the seal over the valve stem and
seat it against the head.
2. Spring with damper, and cap.
3. Valve keepers.
(figure 5).
them in place.
Carefully release spring pressure. Make sure
the valve keepers stay in place.
4. Spark plugs.
5. Rocker arms, as outlined previously.
- Old gaskets from the block, heads, and intake

manifold.
Excessive carbon deposits from the exhaust and
EGR passages.
passages.
L*
Inspect

1 . Front and rear intake manifold seals to the block.
2. Side gaskets to the cylinder heads.
3. Intake manifold and bolts.
Bolts to 40 N m (30 ft. lbs.). Use the tightening

sequence shown in figure 6 .
4. Front generator/AIR pump bracket (TBI engines) or
upper generator bracket (carbureted engines).
equipped).
MAP sensor with bracket (TBI engines).
EGR solenoid with bracket (TBI engines).
6A5-6 7.4 LITER V8
G)
dD
Q)
FRONTI
F-02377
Figure 6intake Manifold Tightening Sequence

8 . Wires at ignition coil (TBI engines).
9. Distributor. Refer to ENGINE ELECTRICAL (SEC

6 D).
10. Vacuum hoses.
11. Crankcase ventilation hoses.
12. Fuel line or lines.
13. Cruise control transducer (if equipped).
14. W iring harnesses to the clips.
15. Accelerator, cruise control, and TV cables.
16. Sensor wire at front of manifold (TBI engines).
17. Heater hose and pipe (TBI engines) or heater hose
(carbureted engines).
18. Water pump bypass hose, heater hose, and upper
radiator hose.
19. Air cleaner.
grade of coolant.
HYDRAULIC LIFTER
REPLACEMENT
++

Tools Required:
J-3049 Lifter Remover (Plier Type) or
Figure 8Removing the Valve Lifter

J-9290-01 Lifter Remover (Slide Hammer Type)
1. Rocker arm cover, intake m anifold, and pushrod, as

place them in an organizer rack. The lifters
must be installed in the same bore from which
they were removed.
J-3049 (figure 7) or J-9290-01 (figure 8 ).
Inspect
Hydraulic lifter body for scuffing and scoring. If the
lifter body wall is worn or dam aged, the mating bore
in the block should also be checked.
Check the fit of each hydraulic lifter in its mating
bore in the block. If the clearance is excessive, try a
new lifter.
The hydraulic lifter foot must be smooth and slightly
convex. If worn, pitted, or dam aged, the mating

Hydraulic lifters to the block. Lubricate the lifter foot
and body with Engine Oil Supplem ent or equivalent.
Im portant
W hen any new h ydrau lic lifters or a new
camshaft is installed, replace the engine oil
a n d filte r. E n g in e O il S u p p le m e n t (o r
equivalent) should be added to the crankcase
oil.
R eplace all h y d ra u lic lifte rs w hen a new
Intake Manifold, as outlined previously.
Pushrod, as outlined previously.
Adjust
Figure 7Removing the Valve Lifter

7.4 LITER V8 6A5-7

ROCKER ARM STUD
REPLACEMENT
previously.
2. Rocker arm stud. Use a deep socket.
Install or Connect
1. Rocker arm stud.
B-09570
Rocker arm stud to 6 8 N-m (50 ft. lbs.).
CYLINDER HEAD
REPLACEMENT
Adjust
1 . Intake manifold, as outlined previously.
EXHAUST MANIFOLD
REPLACEMENT
0
1.
2.
3.
4.
5.
6.
7.
8.
9.

Heat stove pipe (right side manifold).
Dipstick tube (right side manifold).
O xyg en se nso r w ire (le ft sid e m a n ifo ld ) (TBI
engines). Do not remove the sensor unless it is to be
replaced.
AIR hose at the check valve.
Spark plugs.
Exhaust manifold bolts and spark plug heat shields.
Exhaust manifold.
2 . Generator, and lay aside (right cylinder head).

3. AIR pump and generator/AIR pump brackets (right
cylinder head on TBI engines).
5. Air conditioning com pressor and front bracket (if
equipped). Lay the compressor aside.
7. Spark plugs.
8. AIR pipe bolts at rear of cylinder head (TBI engines).
Push the pipe out of the way.
9. Ground strap at the rear of the cylinder head.
10. Sensor wire at the cylinder head.
13. Cylinder head.
14. Head gasket.
Clean
block.
Cylinder head bolt threads and threads in the block.
IQR Clean
Mating surface on the manifold and head.
Install or Connect
1. Exhaust manifold.
2. Exhaust manifold bolts and spark plug shields.
L*
Inspect

Tighten
Exhaust manifold bolts to 54 N-m (40 ft. lbs.).
Tighten the center bolts first, then con
tinue outward each way.
3.
4.
5.
6.
Exhaust pipe.
Spark plugs.
AIR hose.
O x yg e n s e n s o r w ire (TB I e n g in e s ) (le ft sid e
manifold).
7. Dipstick tube (right side manifold).
8 . Heat stove pipe (right side manifold).

1. Head gasket.
even.
. Do n o t use s e a le r on c o m p o s itio n
steel-asbestos gaskets.
Place the gasket over the block dowel pins
with the bead up.
2. C ylinder head. Carefully guide the cylinder head
into place over the dowel pins and gasket.
6A5-8 7.4 LITER V8
Figure 10Removing the Torsional Damper

3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound (GM part number
Figure 11Installing the Front Crankshaft Seal

7. F ro n t c ra n k s h a ft s e a l. P ry o u t w ith a la rg e
screwdriver. Take care not to distort the front cover.
8 . Crankshaft key, if necessary.
Tighten

sequence shown in figure 9. Proper torque is
110 N m (80 ft. lbs.).
Adjust
5. Sensor wire.
6 . Ground strap at the rear of the cylinder head.
7. AIR pipe to the rear of the cylinder head (TBI
engines).
8 . Rocker arm cover, as outlined previously.
9. Spark plugs.
10. Air conditioning com pressor and front bracket (if
equipped).
12. AIR pump and generator/AIR pump brackets (right
cylinder head on TBI engines).
13. Generator (right cylinder head).
Inspect
Oil seal contact area on the torsional dam per shaft
for grooving and roughness. Replace if necessary.
4- Install or Connect (Figures 11 and 12)
Tools Required:
J-2 3 5 2 3 -E T o rs io n a l D a m p e r P u lle r and
Installer
open end of the seal faces inside the engine. Coat
the seal lips with engine oil.

REPLACEMENT
1.
2.
3.
4.
5.
6.
Tool Required:
J-2 3 5 2 3 -E T o rsio n a l D a m p e r P u lle r and
Installer
Torsional dam per bolt.
A. In s ta lla tio n S tud

B. N u t
C. W a s h e r and B e a rin g
B-07880
Figure 12Installing the Torsional Damper
7.4 LITER V8 6A5-9
N OTICE: The in ertia w e ig h t section o f the

follow ed or m ovem ent of the inertia weight
section of the hub will destroy the tuning of the
torsional damper.
3. Stud (item A, figure 12) to the crankshaft. Thread the
Torsional damper over the end of the stud. Align the
keyway in the torsional dam per shaft w ith the
crankshaft key.
Use a small amount of RTV sealer to seal the
crankshaft key to crankshaft joint.
Bearing, washer and nut (figure 12).
Turn the nut to pull the vibration damper into
place.
Remove the tool.
6. Torsional dam per bolt and washer.
Tighten
Cut the front oil pan seal flush with the block
on both sides (figure 13). Use a sharp cutting
tool to ensure a clean cut.
Pull off the front cover.
7. Gasket and front oil pan seal.


4- +

2. Water pump. Refer to ENGINE COOLING (SEC.
6 B).
4. Oil pan to front cover bolts.
5. Front cover to block bolts.
6 . Front cover.
Pull the cover forw ard enough to p erm it
cutting of the front oil pan seal (figure 13).
Figure 16Applying Sealer
6A5-10 7.4 LITER V8

8 . Front crankshaft oil seal from the front cover. Pry out

cover.
5 2 Clean
Old gasket from the front cover, block, and oil pan.
Inspect
necessary.
1.
2.
3.
4.
5.
Tool Required:
Front crankshaft seal. Use J-22102 (figure 14). The
open end of the seal faces inside the engine. Coat
the seal lips with engine oil.
Front oil pan seal.
Cut the tabs from a new seal (figure 15). Use a
sharp cutting tool to ensure a clean cut.
Position the seal on the front cover. Push the
seal locating tips into the holes in the front
cover.
Front cover to block gasket to the front cover. Use
gasket sealer to hold it in position.
Apply a 3 mm (Vs-inch) bead of RTV sealant (GM
part num ber 1052366 or equivalent) to the front oil
pan to block joint (figure 16).
Front cover to the engine. Press the cover down
against the oil pan until the block dowel pins align
with the holes in the cover. Position the cover
against the block so that the dowels enter the cover
holes without binding. Do not force the cover over
the holes. Do not distort the cover flange or dowel
pin holes. Hold the front cover in this position. Install
and partially tighten the oil pan to front cover bolts.
Front cover to block bolts.
A. A pply RTV Sealer to Shaded Area

G asket
R einforcem ent
Rear Oil Pan Seal
T im ing M arker (Some Engines)
Front O il Pan Seal
C lip (N um ber and Location Varies)
74.
75.
76.
77.
78.
79.
F-02382
Tighten
Front cover to block bolts to 10.8 N m (96 in.

lbs.).
Oil pan to front cover bolts to 7.9 N m (70 in.
lbs.).
6 . Torsional damper, as outlined previously.
6 B).
8 . Battery negative cable.
OIL PAN REPLACEMENT

1.
2.
3.
4.
5.
6.
7.

Fan shroud from the radiator and push rearward.
Air cleaner.
Distributor cap.
stands.
Starter (vehicles with manual transmission).
Torque converter or clutch cover.
Oil filter.
Figure 17Oil Pan

NOTICE: Oil pressure line must be removed
from the side of the block to prevent crushing
of the line when the engine is raised.
8 . Oil pressure line from the side of the block.

to the small clearance betw een the oil pan and
Support the engine with a suitable lifting fixture.
9. Engine m ounting through-bolts.
Raise the engine only enough to permit oil pan
removal.
10. Oil pan bolts, tim ing m arker (if used), clips, and
reinforcements.
11. Oil pan.
1 2 . Gaskets and seals.
7.4 LITER V8 6A5-11

jQ * Clean
++
Apply RTV sealer to the front and rear corners of the

gaskets (74).
1. Gaskets (74) to the block. Use gasket sealer to hold
them in place.
2. Rear oil pan seal (76) to the groove in the rear main
bearing cap, with the ends mating against the
gaskets (74).
3. Front oil pan seal (78). Press the locating tips into
the holes in the front cover. The ends should mate
against the gaskets (74).
4. Oil pan.
5. Oil pan bolts, tim ing m arker (if used), clips, and
reinforcements.
Oil Pump Repair

lbs.).

+- Install or Connect
Oil pan to block bolts to 18.1 N m (160 in. lbs.).

1. Oil pump to the engine. Align the slot in the oil
pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
gasket is used.
2 . Oil pump to main bearing cap bolt.
Lower the engine.

NOTICE: See N o tice on page 6 A 5 - 1 of this
section.
6 . Engine mounting through bolts.
Oil pump bolt to 90 N m (65 ft. lbs.).

Tighten
T h ro u g h -b o lts to s p e c ific a tio n s . R efer to
figures 35, 36, and 37.
REAR CRANKSHAFT OIL

SEAL REPLACEMENT
7. Oil pressure line.

8 . Oil filter.
9. Torque converter or clutch cover.

10. Starter (if removed).
Lower the vehicle.
11. Distributor cap.
12. Air cleaner.
13. Fan shroud.
The rear main bearing oil seal can be replaced (both

halves) without removal of the crankshaft. Always replace
the upper and lower seal as a unit. Install the seal with the
lip facing the front of the engine. Extreme care should be
exercised when installing this seal to protect the sealing
bead located in the channel on the outside diameter of
the seal. An installation tool should be used to protect the
seal bead when positioning the seal. (Some seal kits
include the tool as part of the service kit).

1.
2.
3.
4.

1 . Oil pan, as outlined previously.
2 . Oil pump to main bearing cup bolt.
Oil pan and oil pump, as outlined previously.

Rear main bearing cap.
Lower seal half (figure 18).
Upper seal half (figure 19).
Tap on the upper seal half, using a small drift
and hammer.
Remove the upper seal half, using pliers.
Clean
3. Oil pump.
Sealing surfaces of the main bearing cap and block.
Inspect
Oil pump pickup tube for damage and looseness. If
the tube is loose or damaged, replace it as outlined
in the proper unit repair manual.
Tighten
I*
Inspect
Crankshaft, seal channel, and sealing surfaces for
nicks, scratches, etc.
6A5-12 7.4 LITER V8
Figure 19Removing the Upper Oil Seal Half

I++I Install or Connect (Figures 20, 21, and 22)
1. Upper seal half.
| ? | Important
An oil seal installation tool (figure 20) should
be fabricated (if not provided in the seal kit) to
prevent seal dam age d urin g in sta lla tio n .
Extreme care should be taken when installing
this seal to protect the sealing bead located in
the channel on the outside diameter of the
seal.
Coat the seal lips lightly with engine oil. Keep the oil
off of the seal mating ends.
Position the tip of the tool between the crankshaft
and the seal seat in the block (figure 2 1 ).
A.
B.
C.
82.
90.
91.
92.
F orw ard
F a b ric a te d Tool
O il Seal Lip
C ra n k s h a ft
U p p e r Seal H a lf
L o w e r Seal H a lf
M ain B earing C ap
F-02380
Figure 21Installing the Rear Crankshaft Oil Seal
C
A
B ->
1
t
A. 4 m m (11/64-inc h)
B. 13 m m (1/ 2 -in ch
C. 0.10 m m (0.004- in c h ) s h im s to c k
Apply Sealant to Shaded Areas Only B-03498

B.0525Q
Figure 20Oil Seal Installation Tool
Figure 22Applying Sealer to the Block
7.4 LITER V8 6A5-13

Position the seal half between the crankshaft and
the tip of the tool. Make sure that the oil seal lip is
positioned toward the front of the engine.
Roll the seal around the crankshaft using the tool as
a shoe-horn to protect the seal bead from the
sharp corner of the seal seat surface in the block.
The installation tool must remain in position until the
seal half is properly positioned with both ends flush
with the block.
Remove the tool, being careful not to withdraw the
seal half.
2 . Lower seal half.
Coat the seal lips lightly with engine oil. Keep
the oil off of the seal mating ends.
Insert the seal half into the rear main bearing
cap. Use the tool to protect the seal half from
the sharp edge of the seal seat. Feed the seal
half into the rear main bearing cap, using light
finger pressure. Make sure the oil seal lip
faces the front of the engine (figure 21).
Rear main bearing cap with the lower main bearing.
Apply a brush-on type oil sealing compound to
the mating surface of the block and cap (figure
22). Do not a llo w any s e a la n t on e ith e r
crankshaft or rear oil seal.
Apply engine oil to the lower main bearing.
Position the cap to the block. Install the cap
bolts.
Rear main bearing cap bolts tem porarily

to 14 N m (10 ft. lbs.).
then forward with a lead hammer. This will line
up the rear main bearing and crankshaft thrust
surfaces.
Tighten
Rear main bearing cap bolts to 150 N-m
110 ft. lbs.).
4. Oil pan and oil pump, as outlined previously.
5. The proper quantity and grade of engine oil.
MEASURING CAMSHAFT
LOBE LIFT
Tools Required:
J-8520 Camshaft Lobe Lift Indicator
2. Refer to figure 23. Position the dial indicator (part of
3. Rotate the crankshaft slowly in the direction of
rotation until the lifter is on the heel of the cam lobe.
At this point, the pushrod will be in its lowest
position.
4. Set dial indicator on zero, then rotate the crankshaft
bum p the engine over, until the pushrod is in fully
raised position.
Im portant
Whenever the engine is cranked remotely at
the starter, with a special jum per cable or
other means, the prim ary leads should be
disconnected from the distributor or ignition
coil.
5. C om pare the to ta l lift recorded from th e d ial
indicator with specifications.
6. If c a m s h a ft re a d in g s fo r all lo b e s are w ith in
26)
Tool Required:
J-1619 Crankshaft Sprocket Puller
6A5-14 7.4 LITER V8
17. Camshaft sprocket and tim ing chain. The sprocket

is a light interference fit on the camshaft. Tap the
sprocket on its lower edge to loosen it.

2. Air cleaner.
3. Grille.
4. Air conditioning condensor from its mounting and
swing it forward.
5. Fan, sh ro ud , and radiator. R efer to EN G IN E
COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2).
6. Generator and bracket.
8. Fuel line (carbureted engines).
6B1).
12. Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
14. P u s h ro d s a nd h y d ra u lic lifte rs , as o u tlin e d
previously.
15. Fuel pump and pushrod (carbureted engines).
Align the tim ing marks (figure 24).
18. Crankshaft sprocket (if required). Use J-1619 (figure

25).
19. Camshaft.
Install two or three 5/ie -1 8 bolts 100-125 mm (4-5
inches) long into the cam shaft threaded holes. Use
these bolts to handle the camshaft (figure 26).
Pull the cam shaft from the block. Use care to
prevent damage to the cam shaft bearings.
Cleaning Inspection and Repair

Clean, inspect and repair or replace the cam shaft and
manual.
T he u nit re p air m anual also d e s c rib e s ca m sh aft

Tool Required:
J-22102 Crankshaft Sprocket Installer
q u a lity engine oil su pp le m en t (GM Engine Oil
Supplem ent or equivalent).
Two or three 5/ie -1 8 bolts 100-125 mm (4 -5 inches)
long into the camshaft threaded holes. Use these
bolts to handle the camshaft.
2 . Cam shaft to the engine (figure 26). Handle the
c a m s h a ft c a re fu lly to p re ve n t d am ag e to the
camshaft bearings.
7.4 LITER V8 6A5-15

C rankshaft sprocket (if removed). Use J-22102
(figure 25). Make sure the tim in g m ark faces
outside.
Camshaft sprocket and tim ing chain.
Important

Tighten
Fuel pump and pushrod (carbureted engines).
H y d ra u lic lifte rs and p u s h ro d s , as o u tlin e d
previously.
| j I Important
Replace all hydraulic lifters, crankcase oil and
filter, and add GM Engine Oil Supplem ent (or
equivalent) to the engine oil whenever a new
jP
Adjust

6D).
6B1).
13. Fuel line (carbureted engines).
15. Generator and bracket.
16. Fan, sh ro ud , and radiator. R efer to E N G IN E
COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2).
17. Air conditioning condensor.
18. Grille.
19. Air cleaner.
grade of coolant.
CONNECTING ROD AND

PISTON REPLACEMENT
E3
1.
2.
3.
4.

Tool Required:
J-5239 Guide Set
C ylinder head, as outlined previously.
bores.
reamer.
Figure 27Replacing the Connecting Rod and Piston

5. Connecting rod cap. Check the connecting rod and
cap for id e n tifica tio n marks. M ark the parts if
required. The connecting rod and cap must be kept
together as mating parts.
Attach J-5239 to the connecting rod bolts
(figure 27).

unit repair manual.
Piston rings.
Cylinder bores.

Tools Required:
Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
Make sure the piston is installed in the m atching
cylinder for which it was fitted. Used pistons must
be installed in the cylinder they were removed from.
6A5-16 7.4 LITER V8

6
ENGINE LEFT
ENGINE FRONT
ENGINE RIGHT
B. 2nd C o m p re s s io n R ing Gap

C. O il R ing S p a c e r G ap
(Tang In H o le O r S lo t W ith Arc)
D. Top C o m p re s s io n R ing Gap
B-07935
Figure 28Ring End Gap Location

size.
connecting rod cap.
Piston and connecting rod to the proper bore.
engine oil.
W ithout disturbing the ring end gap location,
The piston must be installed so that the valve
clearance notches are towards the center of
the engine (figure 30).
Place the piston in its matching bore. Using
light blows with a hammer handle, tap the
piston down into its bore (figure 29). At the
same time, from beneath the vehicle guide the
connecting rod to the crankpin with J-5239
(figure 27). Hold the ring compressor against
the block until all rings have entered the
cylinder bore.
Im portant
Each connecting rod and bearing cap should
be m arked, beginning at the front of the
engine. Cylinders 1, 3, 5 and 7 are the left
bank and 2, 4, 6 and 8 are the right bank. The
numbers on the connecting rod and bearing
cap must be on the same side when installed
in the cylinder bore. If a connecting rod is ever
transposed from one block or cylind er to
another, new connecting rod and bearings
should be fitted and the connecting rod should
be num bered to correspond with the new
cylinder number.
tU
Measure

Tighten
Connecting rod cap nuts to 66 N m (48 ft. lbs.),
tjj
Measure
g a g e b e tw e e n th e c o n n e c tin g rod and
crankshaft (figure 31). The correct clearance is
0.013-0.023-inch.
7.4 LITER V8 6A5-17


3. Oil filter.
4. Engine oil, as needed.

1. Oil filter.
]?
Tighten
Inspect
Bypass valve spring and valve disc for proper

operation, cracks, and damage. If replacement
is needed, the oil filter bypass valve (93) must
be replaced, as follows:
++
2. Bolts (94).
1.
2.
3.
4.
3. Oil filter bypass valve.
Clean
Valve chamber in the block.

1. Oil filter bypass valve (93).
5.
2. Bolts (94).
6.
8.

Tool Required:
Spark plugs.
Main bearing caps.
markings. Mark the caps if necessary. The
ca ps m ust be retu rne d to th e ir o rig in a l
locations during assembly.
caps.
Rear crankshaft oil seal, if necessary, as outlined
previously.
Insert J-8080 into the crankshaft oil hole
(figure 33).
Rotate the crankshaft to turn the bearing
insert out of the block.
A. Valve D isc
93. O il F ilte r B yp ass Valve
94. B o lt
Figure 32Oil Filter Bypass Valve

Crankshaft.
Main bearing cap replacem ent (shim m ing
procedure).
Instair or Connect (Figures 22, 33, and 34)

B-05286
Tool Required:
6A5-18 7.4 LITER V8

Insert tool J-8080 into a crankshaft main
bearing oil hole (figure 33).
Insert the plain end (without the bearing tang)
of the insert between the crankshaft and the
Rotate the crankshaft to roll the insert into
the block.
Remove the tool.
2. Lower main bearing inserts to the main bearing
caps.
Measure
Main bearing clearance. Refer to the
proper unit repair manual. If the engine
is in the vehicle, the crankshaft must be
s u p p o rte d u p w a rd to re m o ve a ny
clearance from the upper bearing. The
total clearance can then be measured
between the lower bearing and journal.
block.
Tighten
Main bearing cap bolts to 150 N m (110 ft. lbs.).

4. Rear crankshaft oil seal to the block and main
bearing cap, as outlined previously.
5. Rear main bearing cap.
22). Do not allow any sealant on either crank
shaft or rear oil seal.
Tighten the bolts temporarily to 14 N m (10 ft.
lbs.).
A. F orw ard
B. F e e le r G age
100. R ear M ain B e aring C ap
101. C ra n k s h a ft
B-07878
Figure 34Measuring Crankshaft End Play
+ Remove or Disconnect
1. Transmission, flywheel housing, and clutch.
2. Flywheel bolts.
3. Flywheel.
Clean
any burrs.
Inspect
Replace the flywheel if necessary. Do not machine
the flywheel.
Measure
Tap th e end of the cra n ksh a ft firs t
re a rw a rd th en fo rw a rd w ith a lead
hammer. This will line up the rear main
bearing and crankshaft thrust surfaces.
Tighten the rear main bearing cap bolts
to 150 N m (110 ft. lbs.).
W ith the cran ksha ft forced forw ard,
bearing with a feeler gage (figure 34).
The
p ro p e r
c le a ra n c e
is
0.006-0.010-inch.
8. Spark plugs.

this will change metal structure.
2. Uniformly heat the flywheel gear to temperature
which will expand the gear to perm it installation.
Temperature must not exceed 200C (400F).
flywheel.
1. Flywheel.
2. Flywheel bolts.
Tighten

7.4 LITER V8 6A5-19

ENGINE MOUNTINGS
m o u n tin g breakag e o ccu rs, the re m ain in g
stresses.

the oil pump screen, jacking against the oil pan
may cause it to be b ent against the pum p
1. R aise the e n g in e to rem ove w e ig h t from the
m ountings and to place a slight tension on the
rubber cushion. Observe both m ountings while
raising the engine.
2. Replace the m ounting if the following conditions
exist:
cracks.
Rubber cushion separated from the metal
plate of the m ounting.
m ounting and its attaching points, lower the engine
and tighten the bolts or nuts attaching the mounting
to the engine, frame, or bracket.
Rear Mountings
Observe the transm ission m ounting.
2. Replace the mounting if the following conditions
exist:
M ounting bottom ed o ut (ta ilsh a ft can be
moved up but not down).
3. If there is relative movement between a metal plate
of the m ounting and its attaching point, tighten the
b o lts o r nuts a tta c h in g th e m o u n tin g to th e
transm ission or crossmember.

+- Remove or Disconnect (Figures 35, 36, and
37)
2. Engine m ounting through-bolt and nut.

between the rear o f the engine and the dash
panel which could cause distributor damage.
Raise the engine only enough to perm it removal of
4. M ounting assembly.

1. M ounting assembly.
NOTICE: See N o tice on page 6 A 5 - 1 o f this
section.
Tighten
Fasteners to specifications. Refer to figures
35, 36, and 37.
3. Engine m ount through-bolt and nut. Lower the
engine until the bolt can be inserted. Install the nut.
Through-bolt nut to specifications. Refer to

figures 35, 36, and 37.
REAR MOUNTING REPLACEMENT

(EXCEPT P-MODELS WITH FLYWHEEL
HOUSING MOUNTING)
40)
screen, resulting in a damaged oil pickup unit.
Support the rear of the engine to relieve the weight
on the rear mountings.
2. Mounting to crossm em ber nut(s) and washer(s).
3. Mounting to transm ission bolts and washers.
4. Mounting.

1. Mounting.
2. Mounting to transm ission bolts and washers.
NOTICE: See N o tice on page 6 A 5 - 1 o f this
section.
6A5-20 7.4 LITER V8
A. F orw ard
B. 40 N-m (30 Ft. Lbs.)
C. Torque B o lt To 115 N-m (85 Ft. Lbs.) Or, Torque N ut To 75 N-m (55 Ft. Lbs.)
D. 48 N-m (36 Ft. Lbs.)
E. Torque B o lt To 48 N-m (36 Ft. Lbs.) Or, Torque N ut To 40 N-m (30 Ft. Lbs.)
151. H eat S h ie ld (E n gine s W ith Federal E m is s io n s L e ft S id e O nly)
B-07714
Figure 35Front Engine Mounting (R Models)
7.4 LITER V8 6A5-21
A.
B.
C.
D.
E.
151.
152.
40 N m (30 Ft. Lbs.)

Torque B o lt to 115 N-m (85 Ft. Lbs.) Or, Torque N ut to 75 N-m (55 Ft. Lbs.)
48 N-m (36 Ft. Lbs.)
65 N-m (48 Ft. Lbs.)
Forw ard
H eat S h ie ld (E n g in e s w ith Federal E m is s io n s -L e ft S ide O nly)
T ra n s m is s io n S tru t B ra cke t (A u to m a tic T ra n s m is s io n ) o r S p a c e r (M anual T ra n s m is s io n s ).
B-07715
Figure 36Front Engine Mounting (V Models)
6A5-22 7.4 LITER V8

A.
B.
C.
D.
Front
100 N m (75 Ft. Lbs.)
48 N m (36 Ft. Lbs.
40 N m (30 Ft. Lbs. (3/a-inch Nut);
65 N m (48 Ft. Lbs.) (7/ie-inch Nut)
151. Heat Shield (Engines w ith Federal Em issions
Side Only)
MODELS WITH I-BEAM AXLE (RPO-FS3)

B-07716
Figure 37Front Engine Mounting (P Models)
Tighten

38, 39, and 40).

(P-MODELS WITH FLYWHEEL
HOUSING MOUNTING)
the oil pump screen, jacking against the oil pan
removal of the m ounting.
3. Engine mounting.
1. Engine m ounting. Align the hole in the m ounting

with the hole in the crossmember.
Lower the engine.
NOTICE: See N otice on page 6 A 5 - 1 of this
section.
Tighten
ENGINE REPLACEMENT
1. Hood.
3. Air cleaner.
7.4 LITER V8 6A5-23
MODELS WITH THM 400 TRANSMISSION (RPO-M40)

A. Forward
B. 48 N m (36 Ft. Lbs.)
B-07921
Figure 38Rear Engine Mounting (R Models)
6A5-24 7.4 LITER V8

1. Engine in the vehicle.

section.
2. Engine m ounting through bolts and nuts.
Tighten
3.
4.
A. 54 N m (40 Ft. Lbs.)

B. 48 N-m (36 Ft. Lbs.)
C. Forw ard
5.
6.
7.
8.
9.
10.
11.
12.
B
B-07897
Figure 39 Rear Engine Mounting (V Models)

4. R a d ia to r and fa n s h ro u d . R e fe r to E N G IN E
COOLING (SEC. 6B).
5. Necessary engine wiring:
Starter and solenoid wires.
Generator wires.
Temperature sensor wire.
Oil pressure sender wire.
Distributor or coil wires.
Any other necessary wiring.
6. Accelerator, cruise control and TVS linkages, as
equipped.
7. Fuel supply line.
8. Necessary vacuum hoses:
Evaporative emission hoses.
Vacuum booster hose (if used).
Cruise control hose (if used).
Any other necessary vacuum hoses.
10. Air conditioning compressor, and lay aside.
stands.
11. Exhaust pipes at the manifolds.
12. Starter.
14. Flex plate to torque converter bolts (autom atic
transmission).
Lower the vehicle.
Support the transm ission.
Attach a suitable lifting fixture.
16. Front engine m ounting through bolts.
17. Engine.
13.
14.
15.
16.
17.
18.

36, 37, and 38.
Bell housing bolts.
Remove the lifting fixture and transmission jack.
stands.
Flex plate to torque co nve rte r bolts (autom atic
transmission).
Flywheel or torque converter cover.
Starter.
Exhaust pipes at the manifolds.
Air conditioning compressor.
Vacuum hoses.
Fuel supply line.
Accelerator, cruise control, and TVS linkages, as
equipped.
Engine wiring.
R a d ia to r and fa n s h ro u d : R e fe r to E N G IN E
COOLING (SEC. 6B).
Air cleaner.
Hood.
Proper quantity and grade of coolant.
7.4 LITER V8 6A5-25
Figure 40Rear Engine Mounting (P Models with Transmission Tail Type Mounting)
6A5-26 7.4 LITER V8
Figure 41Rear Engine Mounting (P Models with

Flywheel Housing Type Mounting)
7.4 LITER V8 6A5-27
SPECIFICATIONS
All Specifications are in INCHES unless otherw ise noted.
GENERAL DATA:
Type
Displacement
RPO
Bore
Stroke
Compression Ratio
Firing Order
Oil Pressure
CYLINDER BORE:
Diameter
Production
Out Of
Service
Round
Production
Taper
V8
7.4L (454 Cu. In.)
L19, LE8
4.25
4.00
7.9:1
1-8-4-3-6-5-7-2
10 psi @ 500 RPM Minimum; 40-60 psi @ 2000 RPM
4.2495-4.2525
0.001 (Maximum)
0.002 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.001 (Maximum)
Thrust Side
Relief Side
Service
PISTON:
Production
Service Limit
PISTON RING:
C
0
Production
uiuu ve
M
0.003-0.004
0.005 (Maximum)
oiecucmoe
H lparanrp
1
0
2nd
0.0017-0.0032
Hi Limit Production +0.001
Top
0.010-0.020
2nd
0.010-0.020
Production
Gap
N
0
1
L
0.0017-0.0032
Service Limit
S
S
Top
Groove
Clearance
PISTON PIN:
Diameter
Clearance
In Piston
Fit In Rod
Service Limit
Production
Service Limit
Production
Service Limit
0.0050-0.0065
0.015-0.055
Production
Service Limit
0.9895-0.9898
0.00025-0.00035
0.001 (Maximum)
6A5-28 7.4 LITER V8
SPECIFICATIONS
DISPLACEMENT
CRANKSHAFT:
7.4 L
Diameter
Main
Journal
Taper
Out Of
Round
Main
Bearing
Clearance
Production
Service Limit
#1, #2, #3, #4

#5
Production
Service Limit
Production
Service Limit
#1,#2, #3, #4
#5
#1, #2, #3, #4
#5
Crankshaft End Play
Crankpin
Taper
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
2.7481-2.7490
2.7476-2.7486
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
0.0013-0.0025
0.0024-0.0040
0.0010-0.0025
0.0025-0.0035
0.006-0.010
2.1990-2.200
0.0005
0.001
0.0005
0.001
0.0009-0.0025
0.003 (Maximum)
0.0013-0.023
CAMSHAFT:
Lobe
Lift 0.002
Journal Diameter
Intake
Exhaust
0.2343
0.2530
1.9482-1.9492
VALVE SYSTEM:
Lifter
Rocker Arm Ratio
Valve Lash
Hydraulic
1.70:1
Intake
Exhaust

Seat Runout (Intake & Exhaust L _
Intake
Seat Width
Exhaust
Intake
Production
Stem
Exhaust
Clearance
Intake
Service
Exhaust
Free Length
Pressure
Closed
Valve
lbs. @ in.
Open
Spring
Installed Height
V32"
Valve Spring Fit In Damper
3U Turn Down From Zero Lash

45
46
0.002 (Maximum)
1/32-1/l6
1/l6-3/32
0.0010-0.0027
0.0012-0.0029
2.12
74-86 lbs. @ 1.80 in.
195-215 lbs. @ 1.40 in.
151/64
7.4 LITER V8 6A5-29
Nm
Ft. L bs.
............................
............................
............................
13.0
40
54
In. Lbs.
115
30
40
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
110
115
10.8
7.9
18.1
90
150
26
66
26
90
9.0
40
40
40
30
80
85
Ite m
Rocker Arm Cover N u t s ...........................................................

Intake Manifold B o lts..................................................................
Rocker Arm S tu d s ......................................................................
Exhaust Manifold Bolts
Cylinder Head Bolts....................................................................
Torsional Damper B o lts .............................................................
Front Cover to Block B o lt s .......................................................
Oil Pan to Front Cover B o lts ....................................................
Oil Pan to Block B o lts ...............................................................
Oil Pump Bolt...............................................................................
Main Bearing C a p s ....................................................................
Camshaft Sprocket B olts...........................................................
Connecting Rod Cap N u t s .......................................................
Oil Filter Bypass Valve B olts....................................................
Flywheel B o lts ............................................................................
Oil Pump Cover B o lts ...............................................................
Flywheel Housing B olts.............................................................
Water Pump B o lts ......................................................................
Water Outlet B o lts ........................ .............................................
Spark P lu g s .................................................................................
65
110
20
48
20
65
30
30
30
22
96
70
160
80
6A5-30 7.4 LITER V8
SPECIAL TOOLS
J-23523-E
2.
J-5239
J-5892-B
8.
J-23590
J-9290-01
J-3049
4.
J-22102
10.
J-1619
5.
J-8080
11.
J-8520
6.
J-8037
1. T o rsio n a l D a m p e r R em ove r and In s ta lle r

2. Valve S p rin g C o m p re s s o r
3. A ir A d a p te r
7 . G u id e Set
4. C ra n k s h a ft Seal In s ta lle r and C e n te rin g Tool

5. M ain B e aring R e p la ce r
6 . P isto n R ing C o m p re s s o r
8 . H y d ra u lic L ifte r R em over (S lid e H a m m e r Type)

9 H y d ra u lic L ifte r R em over (F lie r Type)
1 0 . C ra n k s h a ft S p ro c k e t P u lle r
11 . Dial In d ic a to r A d a p te r
B-07719
Special Tools
6A6-1
SECTION 6A6
6.2L D IESEL
T he follow ing N otice app lie s to one or m ore steps in the a ssem bly procedure of com p on en ts in th is portion of
the m anual as indicated at appro priate locations by the te rm ino log y NOTICE: See N otice on page 6 A 6-1 of th is
s e c tio n .
NOTICE: All enginefastenersareimportant attachingpartsin that theycouldaffect theperformanceof vital

components and systems, and/or could result in major repair expense. Theymust be replaced with one of
the samepart number or with an equivalent part if replacement becomes necessary. Donot use areplace
ment part of lesser quality or substitute design. Torque values must beusedasspecified during reassembly
to assureproper retention of this part.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ................................................................................................................................................................ 6A 6- 2

Engine L u b rica tio n ............................................................................................................................................... 6A6- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 6A6- 3
Intake Manifold R e p lace m e n t............................................................................................................................6A6- 3
Exhaust Manifold R eplacem ent.........................................................................................................................6A 6- 3
Rocker Arm Cover R e p la c e m e n t..................................................................................................................... 6A 6- 4
Rocker Arm, Shaft, and Pushrod R e p la ce m e n t........................................................................................... 6A 6- 5
Hydraulic Lifter R e p la ce m e n t............................................................................................................................6A 6- 6
Valve Stem Seal and Valve Spring R e p la ce m e n t......................................................................................... 6A 6- 8
Cylinder Head R e p la ce m e n t..............................................................................................................................6A 6- 9
Oil Pump Drive R e p la c e m e n t............................................................................................................................6A6-12
Torsional Damper and Front Crankshaft Seal R e p la ce m e n t......................................................................6A6-12
Front Cover R e p lace m e n t.................................................................................................................................. 6A6-13
Tim ing Chain and Sprocket R eplacem ent...................................................................................................... 6A6-14
Camshaft R e p la ce m e n t.......................................................................................................................................6A6-14
Dipstick Tube Replacement................................................................................................................................ 6A6-16
Oil Pan Replacement (R and V M o d els).......................................................................................................... 6A6-17
Oil Pump Replacement (R and V M o d e ls )...................................................................................................... 6A6-18
Oil Pan and Oil Pump Replacement (G M o d e ls )........................................................................................... 6A6-18
Rear Crankshaft Oil Seal R e p la c e m e n t.......................................................................................................... 6A6-18
Connecting Rod and Piston R eplacem ent...................................................................................................... 6A6-21
Main Bearing R eplacem ent............. .................................................................................................................. 6A6-22
Crankshaft R eplacem ent.................................................................................................................................... 6A6-24
Oil Filter Bypass Valve R eplacem ent...............................................................................................................6A6-24
Engine M ountings................................................................................................................................................. 6A6-25
Engine R e p la ce m e n t......................................... ................................................................................................. 6A6-28
S pecifica tio ns............................................................................................................................................................ 6A6-33
Special T o o ls ............................................................................................................................................................ 6A6-36
6A6-2 6.2 L DIESEL
DESCRIPTION
13
A.
B.
C.
D.
F orw ard
To O il C o o le r
F rom O il C o o le r
F rom O il P um p
10.
11.
12.
13.
14.
15.
16.
17.
18.
R o cke r A rm
C a m s h a fl: B e a rin g s
O il C o o le r B yp a ss Valve
O il F ilte r B yp ass Valve
O il F ilte r
C up Plug
Plug
Valve L ifte rs
P u shro d
F-08022
Figure 1Lubrication Diagram

6.2 L diesel engines are 90 degree V8 type, naturally
aspirated, with indirect type combustion chambers.
three (center) main bearing.
ted to the overhead valves by roller type hydraulic lifters,
pushrods, and spindle mounted rocker arms. The valve
guides are integral in the cylinder head.
sert type crankpin bearings. The piston pins are retained
by snap rings.
ENGINE LUBRICATION
A lubrication schem atic is shown in figure 1.
The gear type oil pum p is driven from either the
vacuum pump shaft or from a drive gear, depending on
engine application. The vacuum pump or drive gear is
driven by the cam shaft. Oil is drawn into the pum p

through a pickup screen and pipe.
Pressurized oil is routed to the oil cooler, located in the
radiator. A bypass valve is provided should the oil cooler
become restricted. Oil flows from the cooler to a full flow
oil filter. An oil filter bypass valve is provided should the oil
filter become restricted.
O il flo w s
fro m
th e
o il f ilt e r
to
th e
o il
galleries, providing pressurized lubrication to various
components.
The hydraulic valve lifters receive oil from the oil
galleries. Oil flows from the hydraulic lifters through
hollow pushrods to the rocker arms. Oil from the overhead
drains back to the crankcase through oil drain holes.
The pistons, piston rings, cylinder walls, and connecting
rod small end bearing are lubricated by oil splash.
6.2 L DIESEL 6A6-3
ON-VEHICLE SERVICE
INTAKE MANIFOLD
REPLACEMENT
3. Intake manifold bolts and fuel line clips.
Tighten
<-- Remove or Disconnect
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Tool R equired:
J-29664 Manifold Cover Set
Battery cables.
Air cleaner.
EGR/EPR solenoids with bracket from the intake
manifold studs.
CDR valve (G models).
EGR and crankcase ventilation hoses.
R ear a ir c o n d itio n in g c o m p re s s o r b ra cke t (if
equipped).
Fuel line bracket and ground strap.
Fuel filter bracket at the intake manifold (G models).
Intake manifold bolts and fuel line clips. On models
w ith g e a r d riv e n va cu u m p u m p s, it m ay be
necessary to loosen the vacuum pump clam p bolt
and turn the pump to provide access to an intake
manifold bolt.
Intake manifold and gasket.
Im portant
If any further service work is to be done, cover
the intake ports with J-29664-1.
Gasket surfaces on intake manifold and cylinder

heads.
1. New gaskets. Be sure to use the correct gasket. The

gaskets fo r ligh t d uty e m issio n s m odels have
openings for the EGR ports, the gaskets for heavy
duty emissions models do not.
Intake manifold.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Intake m an ifold bolts to 42 N m (32 ft. lbs.).

U se th e tig h te n in g s e q u e n c e s h o w n in
fig ure 2.
Rotate the vacuum pump to the proper position and
tighten the clam p bolt (gear driven vacuum pumps).
Fuel filter bracket (G models).
Fuel line bracket and ground strap.
R ear a ir c o n d itio n in g c o m p re s s o r b ra c k e t (if
equipped).
EGR and crankcase ventilation hoses.
CDR valve (G models).
EGR/EPR solenoids with bracket.
Air cleaner.
Battery cables.
EXHAUST MANIFOLD
REPLACEMENT
R AND V MODELS (RIGHT SIDE)
++
1. Battery cables.
stands.
2. Exhaust pipe from the manifold.
Lower the vehicle.
3. Glow plug wires.
4. Air cleaner duct bracket.
5. Glow plugs.
6. Exhaust manifold bolts and exhaust manifold.
Clean
Sealing surfaces on exhaust manifold and cylinder
head.
6A6-4 6.2 L DIESEL

Threads on manifold bolts.
|-K-| Install or Connect

1. Exhaust manifold and bolts.
\^X\ Tighten
2.
3.
4.
5.
6.

Glow plugs.
Air cleaner duct bracket.
Glow plug wires.
stands.
Exhaust pipe to the manifold.
Lower the vehicle.
Battery cables.
R AND V MODELS (LEFT SIDE)
++
1.
2.
3.
4.
5.
6.
7.
Battery cables.
Dipstick tube.
Glow plugs.
equipped).
Exhaust manifold bolts.
stands.
Exhaust manifold, from below the vehicle.
Sealing surfaces on the exhaust m anifold and

cylinder head.
Install or Connect
1. Exhaust manifold, from below the vehicle. Loosely

install two or three bolts to hold the manifold in
place.
Lower the vehicle.
3. R e m a in in g e x h a u s t m a n ifo ld b o lts and a ir
conditioning com pressor rear bracket (if used).
Clean
Sealing surfaces on the exhaust m anifold and
cylinder head.
Threads on the manifold bolts.
Install or Connect
Exhaust manifold.
E x h a u s t m a n ifo ld b o lts and a ir c o n d itio n in g
com pressor rear bracket (if equipped) (left side
exhaust manifold).
Tighten
3. Glow plug wires.
4. Engine cover.
stands.
7. Battery cables.
ROCKER ARM COVER

REPLACEMENT
R AND V MODELS (BOTH SIDES)
G MODELS (RIGHT SIDE)
2. Fuel in je c tio n lin e s . R e fe r to D IE S E L F U E L
INJECTION (SEC. 6C2). (Injection lines for #5 and
#7 cylinders do not have to be removed for right side
rocker arm cover replacement).
3. Glow plug wires (G models).
4. W iring harness from wiring harness clip.
5. W iring harness bracket (left rocker arm cover).
NOTICE: Do not pry on the rocker arm cover.
Damage to sealing surfaces may result.
7. Rocker arm cover.
jQV Clean
4. Glow plugs.
5. Dipstick tube.
6. Battery cables.
G MODELS (BOTH SIDES)

1. Battery cables.
stands.
Lower the vehicle.
3. Engine cover.
4. Glow plug wires.
5. A ir c o n d itio n in g c o m p re s s o r re a r b ra c k e t (if
equipped) (left side exhaust manifold).
6. Exhaust manifold bolts and exhaust manifold.
1. RTV from the rocker arm cover and cylinder head.

All loose RTV, or pieces that will cause installation
interference, must be removed.
2. Oil and grease from the sealing surfaces on the
rocker arm cover and cylinder head. Use a suitable
solvent.
Inspect
Rocker arm cover sealing flanges for distortion.

NOTICE: Do not allow RTV sealant into the
rocker arm cover bolt holes. This may cause a
hydraulic lo ck condition when the bolts are
tightened, damaging the cylinder head casting.
Apply a 5 mm (3/ie-inch) bead of RTV sealant (GM
6.2 L DIESEL 6A6-5

Inspect
Rocker arm cover sealing flanges for distortion.

NOTICE: Do not allow RTV sealant into the
rocker arm cover bolt holes. This may cause a
hydraulic lo c k condition when the bolts are
tightened, damaging the cylinder head casting.
Figure 3A pplying Sealant to the

Rocker Arm Cover
2. Rocker arm cover bolts and fuel return bracket.
part number 1052915 or equivalent) to the cylinder

head, inboard of the bolt holes. Refer to figure 3.
The sealer must be wet to the touch when the bolts
are torqued.
Tighten

W iring harness bracket.
W iring harness to the w iring harness clip.
G low plug w ires (G m odels).
Fuel in je c tio n lines. R efer to D IE S E L F U E L
IN JEC TIO N (SEC. 6C2).
Intake m anifold, as o utline d previously.
G MODELS (LEFT SIDE)

|<-+| Remove or Disconnect
1. Intake m anifold, as o u tlin e d previously.
2. Fuel in je c tio n line s. R efer to D IE S E L F U E L
IN JEC TIO N (SEC. 6C2).
3. U pper fan shroud (vehicles w ith a ir cond itio nin g).
4. A ir co nd itio nin g co m p re ssor belt (if equipped).
5. L eft e xh a u st m a n ifo ld , as o u tlin e d p re v io u s ly
(vehicles w ith air co nd itio nin g).
6. A ir co n d itio n in g co m p re ssor (if equipped). Refer
to AIR C O N D ITIO N IN G (SEC. 1B).
7. D ipstick tu be fron t bracket from stud.
8. W iring harness brackets.
9. R ocker arm cover bolts and fuel return bracket.
NOTICE: Do not pry on the rocker arm cover.
Damage to the sealing surfaces may result.
1. RTV from the rocker arm cover and cylinder head.

All loose RTV, or pieces that will cause installation
interference, must be removed.
2. Oil and grease from the sealing surfaces on the
rocker arm cover and cylinder head.'U se a suitable
solvent.
7.
8.
9.
10.

W iring harness brackets.
Dipstick tube front bracket.
Air conditioning compressor (if equipped). Refer to
AIR CONDITIONING (SEC. 1B).
Left exhaust m anifold, as outlined previously (if
removed).
Air conditioning compressor belt (if equipped).
Upper fan shroud (if removed).
Fuel in je c tio n lin e s . R efer to D IE S E L F U E L
INJECTION (SEC. 6C2).
ROCKER ARM, SHAFT, AND

PUSHROD REPLACEMENT
+ + Remove or Disconnect (Figures 4 and 5)
Rocker arm shaft nuts.
R ocker arm s h a ft w ith rocker arm s. M ark the
assem blies so they can be returned to the original
location at assembly.
Pushrods.
Im portant
The pushrods must be installed in the original
direction at assembly. This is because the
pushrods have a different degree of hardness
at each end. A paint stripe identifies the upper
end of the pushrod. If the paint stripe is not
visible, mark the pushrods on the upper end
as they are removed.
The pushrods should be installed in the same
location at assembly.
5. Rocker arms, if required.
Insert a screwdriver into the rocker arm shaft
bore, and break off the end of the nylon rocker
arm retainers.
Remove the rocker arm retainers with pliers
(figure 5).
Slide the rocker arms from the shaft.

1. Rocker arms to the rocker arm shaft. One type of
rocker arm is used at all locations.
6A6-6 6.2 L DIESEL
Figure 4Valve Train Components

Im portant
Lubricate the rocker arms with engine oil
before installing.
2. Rocker arm retainers.
Center the rocker arms on the corresponding
holes in the rocker arm shaft.
Install new retainers. Use a drift of at least 13
mm (1/2-inch) diameter.
Rotate the engine counterclockwise 88 mm

( 3 1/2 -in c h e s ), m e a s u re d at th e to rs io n a l
damper. This measurem ent can be estimated
by aligning the torsional dam per mark with the
first lower water pump bolt (figure 6). This
procedure will position the engine so no valves
are close to a piston crown.
Install both bolts snug on the shaft.
Tighten
NOTICE: The pushrods must be installed with
the marked or painted end up. Failure to do so
may result in damage or premature wear.
3. Pushrods, with the painted or marked end up.
4. Rocker arm shaft assembly. Make sure the ball ends
of the pushrods seat in the rocker arms.
NOTICE: Im proper installation of the rocker arm
s h a ft b o lts m ay c a u s e r o c k e r arm s h a ft
breakage and/or piston to valve contact.
5. Rocker arm shaft bolts.
Rotate the e n g in e u n til the m ark on the
torsional dam per aligns with the 0 mark on
the tim ing tab.
Bolts alterna te ly to 55 N m (40 ft. lbs.).

HYDRAULIC LIFTER
REPLACEMENT
Tool Required:
J-29834 Hydraulic Lifter Remover (R and V
Models)
2. Rocker arm shaft with rocker arms and pushrods, as
Rocker arm assem blies and pushrods must be

m arked for p ro pe r assem bly, as o u tlin e d
previously.
3. Cylinder head, as outlined later (G models).
4. Clamps (32).
5. G u ide plates (33). Use m ech an ical fin ge rs, if
necessary.
6. Hydraulic lifters, through the access hole in the
cylinder head. On R and V Models, use J-29834
(figure 7) and a magnet. Place the lifters in an
organizer rack. The lifters must be installed in the
same bore from which they were removed.
6.2 L DIESEL 6A6-7
B-08027
Figure 6A ligning the Tim ing Mark
1*
Inspect
Im portant
H ydraulic lifte r body for scu ffing and scoring.

Replace the lifter if present.
Prime new hydraulic lifters before installation

by working the lifter plunger while submerged
in clean kerosene or diesel fuel.
Roller for looseness and excessive play. Check for

m issing or broken needle bearings. R eplace if
necessary.
Roller surface for pits and roughness. If present, the
mating camshaft lobe should also be checked. If the
lobe is pitted or rough, replace both camshaft and
lifter.

Im portant
S o m e e n g in e s w ill have b o th s ta n d a rd and
0.010-inch oversize hydraulic lifters. The oversize
lifter will have a 10 etched on the side. The block
will be stamped O.S. on the cast pad adjacent to
the lifter bore and on the top rail of the cylinder case
above the lifter bore.
Install o r Connect (Figure 4)

NOTICE: New hydraulic lifters must be prim ed
before installation. Damage to the lifters may
result if dry when the engine is started.
1. Hydraulic lifters to the engine. On R and V models,
fabricate an installation tool from m echanics wire.
C o a t th e lifte r ro lle r and b e a rin g s w ith

lu b ric a n t (GM p a rt n u m b e r 1052365 or
equivalent).
Lifters MUST be installed in th eir original
locations.
2. Guide plates (33).
3. Clam ps (32).
Tighten
Clamp bolt to 26 N m (18 ft. lbs.).
Im portant
A fte r a ll c la m p s are in s ta lle d , tu rn th e
cran ksha ft by hand 720 degrees (two full
turns), to insure free movement of the lifters in
the guide plates. If the engine will not turn over
by hand, one or more of the lifters may be
binding in the guide plate.
4. Cylinder head, as outlined later (G models).
5. Rocker arm shaft with rocker arm s and pushrods, in
th e ir o rigin al locations, as outline d previously.
Hardened ends of the pushrods must face up.
6A6-8 6.2 L DIESEL

J-26513-A
J-29666
F-02468
Figure 9Compressing the Valve Spring

2. Rocker arm shaft with rocker arms, as outlined
previously. Mark the assem blies so they can be
returned to their original locations.
3. Glow plugs.
4. Valve keepers.
Rotate the engine until the piston for the
cylinder being serviced is at TDC.
F-02467
Install J-29666 into the glow plug hole.
Figure 7Removing the Hydraulic L ifte r

(R and V Models)

place.
VALVE STEM SEAL AND

Use J-26513-A to compress the valve spring

(figure 9). If the spring will not compress, tap
on the tool lightly with a mallet to break the
cap or rotator loose from the valve keepers.

Tools Required:
J-29666 Air Line Adapter
J-26513-A Valve Spring Compressor
40.
41.
42.
43.
Valve K e ep e r
C ap
S h ie ld
Valve Seal

C arefully release sp ring tension. Remove
J-26513-A.
5. Cap or rotator, shield, and valve spring with damper.
6. Valve seal.
Tools Required:
J-29666 Air Line Adaptor
J-26513-A Valve Spring Compressor
1. New valve seal.
2. Valve spring with damper, shield and cap or rotator.
3. Valve keepers.
W ith air pressure applied to the cylinder with
J-29666, co m p re ss the valve s p rin g w ith
J-26513-A (figure 9).
them in place.
43
44. Valve S p rin g w ith D a m p e r

45. In ta ke Valve
46. R o ta to r
47. E xh a u s t Valve
p-02411

Remove J-26513-A and J-29666.
5. Glow plugs.
6. Rocker arm shaft with rocker arms, as outlined
previously.
Figure 8Valves and Components
6.2 L DIESEL 6A6-9

Im portant
CYLINDER HEAD
REPLACEMENT
REMOVAL (R AND V MODELS) (BOTH SIDES)
2. Injection lines. Refer to DIESEL FUEL INJECTION

(SEC. 6C2).
4. Dipstick tube (left cylinder head).
5. Ground wire at the cowl (right cylinder head).
6. Glow plug relay (left cylinder head).
Raise the vehicle. S upport with suitable safety
stands.
7. Exhaust pipe from the manifold.
Lower the vehicle.
8. Air conditioning com pressor (if equipped) and lay
aside (left cylinder head).
9. Generator, and lay aside (right cylinder head).
10. Glow plug wires.
11. Glow plug temperature inhibit switch wire (right
cylinder head).
12 Rocker arm assem blies and pushrods, as outlined
previously.
13.
14.
15.
16.
17.
18.
19.
REMOVAL (G MODELS) (LEFT SIDE)

Important
13.
14.
15.
16.
17.

m arked fo r p ro pe r assem bly, as o u tlin e d
previously.
Radiator, bypass and heater hoses.
Ground strap.
Water crossover pipe/therm ostat housing assembly.
Cylinder head bolts. Rear bolt in left cylinder head
may have to remain in the head during removal.
Cylinder head.
REMOVAL (G MODELS) (RIGHT SIDE)

B
(SEC. 6C2).
3. Transducer (cruise control equipped vehicles).
4. Upper fan shroud and air conditioning compressor
belt (vehicles with air conditioning).
stands.
6. Rear air conditioning compressor bracket at the
exhaust manifold (if equipped).
7. Glow plug wires.
Lower the vehicle.
8. Air conditioning compressor (if equipped). Refer to
9. Dipstick tube front bracket from the stud.
10. Oil fill tube upper bracket.
12. Rocker arm assemblies and pushrods, as outlined
previously.
Rocker arm assemblies must be marked for

proper assembly, as outlined previously.
Air cleaner resonator and bracket.
Heater, radiator and bypass hoses at the engine.
Generator upper bracket.
Water crossover pipe/therm ostat assembly.
C ylinder head.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Intake m anifold, as outlined previously.

Injection lines at the injection pump. Refer to
DIESEL FUEL INJECTION (SEC. 6C2).
Transducer (cruise control equipped vehicles).
Upper fan shroud and air conditioning compressor
stands.
Left exhaust m anifold, as outlined previously.
Power steering pump lower adjusting bolts.
Glow plug wires.
Glow plug temperature inhibit switch.
Injection lines. Refer to DIESEL FUEL INJECTION
(SEC. 6C2).
Lower the vehicle.
Air conditioning com pressor (if equipped). Refer to
Upper power steering pum p brackets. Lay the pump
aside.
Dipstick tube front bracket from the stud.
Transmission detent cable.
Glow plug controller, bracket, and relay.
W iring harness bracket.
Vacuum line clip, at the cylinder head.
Fuel return line bracket.
Rocker arm assem blies and pushrods, as outlined
previously.
Im portant
20.
21.
22.
23.
24.
25.
Rocker arm assemblies must be marked for

proper assembly, as outlined previously.
Transmission dipstick tube at the front attaching
stud and lay aside.
Water crossover pipe/therm ostat assembly.
C ylinder head bolts.
C ylinder head.

b lo c k . Use o f a m oto rize d w ire b ru s h is not
recommended.
6A6-10 6.2 L DIESEL

A d d itio n a l s e a le r m ay ca u se leakage or
m alfunction. In addition, some sealers may
attack the sealant already on the head gasket.
2. Rear cylinder head bolt to the cylinder head (left
c y lin d e r head). A p p ly s e a la n t to th e b o lt as
described in step 4. Due to clearances, the bolt
must be installed at this time.
3. C ylinder head. Make sure the gasket surfaces are
clean. Guide the head carefully into place over the
dowel pins.
Make sure the bolt threads are clean.
Apply sealant (GM part num ber 1052080 or
equivalent) to the bolt threads and under the
bolt heads.
Tighten
Cylinder head bolt threads using a wire brush.
Metal chips and dirt from the threads in the block.
I?
Inspect
Cylinder head for cracks between the intake and

exhaust ports. Use the m agnaflux or dye method if
available.
Cylinder head bolts, as follows:

U sing the sequ en ce show n in fig u re 10,
tighten all bolts to 25 N-m (20 ft. lbs.).
In sequence, tighten all bolts to 65 N-m (50 ft.
lbs.).
In sequence, tighten all bolts an additional 90
degrees ( 1/4 turn).
5. Water crossover pipe/therm ostat assembly. Use new
gaskets.
Block for missing or damaged dowel pins, or dowel

pins in the wrong location.
Measure
Cylinder head warpage. If warped more than 0.15
mm (0 .0 0 6 -in c h ) lo n g itu d in a lly o r 0.08 mm
(0.003-inch) transversely, replace the cylinder head.
Resurfacing is not recommended.
Pre-cham ber installed depth. The pre-cham ber
s h o u ld be flu s h to a m a x im u m of 0.05 mm
(0.002-inch) protrusion.
Make the measurement at two or more points
on the pre-cham ber where the prechamber
seats on the head gasket shield and sealing
ring.
Measure the difference between the flat of the
p re -ch a m b e r and the fla t surfa ce of the
cylinder head.
The pre-cham ber must not protrude out of the
cylinder head more than 0.05 mm (0.002-inch).
The pre-chamber must not be recessed into
the cylinder head.
CYLINDER HEAD REPAIR

INSTALLATION (R AND V MODELS) (BOTH SIDES)

1. Head gasket to the block, over the dowel pins.
Im portant
The block gasket surfaces must be clean.
DO NOT use a sealer on the head gasket. The
head gasket is manufactured with the proper
amount of sealant printed on its surface.

6. Ground strap.
7. Radiator, bypass, and heater hoses.
8. Pushrods and rocker arm assem blies, in th eir
o rig in a l lo c a tio n s , as d e s c rib e d p re v io u s ly .
9. Glow plug temperature inhibit switch wire (right
cylinder head).
11. Generator (right cylinder head).
12. A ir co n d itio n in g com pressor (left side cylind er
head).
stands.
Lower the vehicle.
14. Glow plug relay (left cylinder head).
15. Ground wire at the cowl (right cylinder head).
16. Dipstick tube (left cylinder head).
(SEC. 6C2).
grade of coolant.
INSTALLATION (G MODELS) (RIGHT SIDE)

| ^ I Im portant
head gasket is m anufactured with the proper
6.2 L DIESEL 6A6-11

A d d itio n a l s e a le r m ay ca use lea kag e or
Cylinder head. Make sure the gasket surfaces are
dowel pins.
3. C ylinder head bolts.
Apply sealant (GM part num ber 1052080 or
bolt heads.
Cylinder head bolts, as follows:

Using the sequence shown in figure 10,
tighten all bolts to 25 N m (20 ft. lbs.).
In sequence, tighten all bolts to 65 N m
(50 ft. lbs.).
In s e q u e n c e , tig h te n a ll b o lts an
additional 90 degrees (1/4 turn).
gaskets.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Heater, radiator, and bypass hoses.
Pushrods and rocker arm assem blies, in th e ir
o rig in a l lo c a tio n s , as d e s c rib e d p re v io u s ly .
Oil fill tube upper bracket.
Dipstick tube front bracket.
Air conditioning com pressor (if equipped). Refer to
stands.
Glow plug wires.
R ear a ir c o n d itio n in g co m p re s s o r b ra c k e t (if
equipped).
Exhaust pipe.
Lower the vehicle.
Upper fan shroud and air conditioning compressor
Transducer (if equipped).
Injection lines. Refer to DIESEL FUEL INJECTION
(SEC. 6C2).
grade of coolant.
A d d itio n a l s e a le r m ay ca u se leakage or
2. Cylinder head. Make sure the gasket surfaces are
dowel pins.
Apply sealant (GM part number 1052080 or
bolt heads.
&
T ig h te n
C ylinder head bolts, as follows:
Using the sequence shown in figure 10,
tighten all bolts to 25 N m (20 ft. lbs.).
In sequence, tighten all bolts to 65 N m
(50 ft. lbs.).
In s e q u e n c e , tig h te n a ll b o lts
additional 90 degrees (1/4 turn).
an

gaskets.
T ig h te n
5. Generator upper bracket.
6. Transmission dipstick tube.
7. Air cleaner resonator and bracket.
8. Pushrods and rocker arm assem blies, in th e ir
o rig in a l lo c a tio n s ; as d e s c rib e d p re v io u s ly .
10. Fuel return line bracket.
11. Vacuum line clip.
12. W iring harness bracket.
13. Glow plug controller, bracket, and relay.
14. Transmission detent cable.
15. Dipstick tube front bracket.
16. Power steering pump and brackets.
stands.
(SEC. 6C2).
19. Glow plug temperature inhibit switch.
21. Power steering pump lower adjusting bolts.
22. Left exhaust manifold, as outlined previously.
INSTALLATION (G MODELS) (LEFT SIDE)

" Install or Connect (Figure 10)
Im p o rta n t
head gasket is manufactured with the proper
Lower the vehicle.

23. Upper fan shroud and air conditioning compressor
24. Transducer (if equipped).
grade of coolant.
6A6-12 6.2 L DIESEL

F orw ard
O il P um p Drive
C lam p
B o lt
G a sket
B-08031
Figure 11Oil Pump Drive
OIL PUMP DRIVE

REPLACEMENT
For gear driven vacuum pump replacement, refer to
VACUUM PUMP (SEC. 6H).
NOTICE: Do not run the engine without the gear
driven vacuum pum p or oil pum p drive in place.
This will cause extensive engine damage.
- *
1.
2.
Bolt and clamp.

Oil pump drive.
3.

Tool Required:
New front crankshaft seal. Use J-22102 (figure 13).
Lubricate the seal lips with engine oil.
Apply engine oil to the crankshaft stub.
Torsional damper. Tap into place with a mallet. Make
sure the key is in place. Make sure the dam per is all
the way on the crankshaft.
Torsional dam per bolt and washer.
Gasket.

1. New gasket to the oil pump drive.
2. Oil pump drive to the engine. Index the drive with
the camshaft gear and oil pump drive shaft. Make
sure the drive seats fully.
3. Clamp and bolt.
Tighten

REPLACEMENT
++
F-02472

Tools Required:
Figure 13Installing the Front Crankshaft Seal
J-23523-E Torsional Damper Puller

1. Battery cables.
2. Upper fan shroud (G models).
Bolt to 270 N-m (200 ft. lbs.)

4. Crankshaft pulley and bolts.

Raise the vehicle (G models). Support with suitable
safety stands.
4. Bolts and crankshaft pulley.
6. Torsional damper. Use J-23523 (figure 12).
7. Front crankshaft seal. Pry out with a screwdriver.

Lower the vehicle, if necessary.
A cce ssory drive belts. Tension as o u tlin e d
ENGINE COOLING (SEC. 6B).
Upper fan shroud (G models).
Battey cables.
in
6.2 L DIESEL 6A6-13
A. A p p ly A n a e ro b ic S e a le r
B. M in im u m C le a ra n ce 1.0 m m (0.040-inch)
80. F ro n t C ove r
81. B a ffle
82. P robe H o ld e r
83. C a m s h a ft G ear
B-08033
Figure 14Front Cover and Components
2. Front cover to the engine. Install the attaching bolts.

6B).
Rotate the engine until the tim ing marks on the
pump gear and cam shaft gear are aligned (figure
15).
Scribe a mark aligning the injection pump flange
and front cover.
3. Four front cover to oil pan bolts.
4. Two fuel return line clips.
5. Injection pump gear.
6. Injection pump retaining nuts at the front cover.
7. Baffle.
8. Front cover bolts.
9. Front cover.
10. Front crankshaft seal. Pry out with a screwdriver.
Tighten
Front cover to block bolts to 45 N m (33 ft.
lbs.).
lbs.).
3. Baffle.
Tighten
Baffle bolts and nut to 45 N m (33 ft. lbs.).

Align the scribe marks on the front cover and
injection pump. If a new front cover was installed,
refer to M arking TDC on the Front Housing in
DIESEL FUEL INJECTION (SEC. 6C2).
4. Injection pump nuts.
RTV from oil pan sealing surface.

Sealing surfaces on front cover.
L * Inspect
F ront co ver fo r cra cks or d am ag e to s e a lin g

surfaces.
Tool Required:
1. New front crankshaft seal to the front cover. Use
J-22102.
Apply a 2 mm (3/32-inch) bead of anaerobic sealant
(GM part num ber 1052357 or equivalent) to the front
cover sealing area shown in Figure 14.
Apply a 5 mm (3/ie-inch) bead of RTV sealant to the
front cover sealing surface that mates against the oil
pan.
A. T im in g M arks
83. C a m s h a ft G ear
84. In je c tio n P um p G ear
B-08034
Figure 15Injection Pump Gear

and Timing Marks
6A6-14 6.2 L DIESEL
A.
83.
90.
91.
T im in g M arks
C a m s h a ft G ear
C a m s h a ft S p ro c k e t
C ra n k s h a ft S p ro c k e t
B-08035
Move the chain inward (parallel to the

front face of the block) the maximum
am o un t w ith fin g e r pressure on the
outside of the chain.
The total indicator travel can be noted.
With used parts, the deflection must not
exceed 20.3 mm (0.800 inch). If the
d e fle c tio n e x c e e d s th is lim it, th e
sprockets and tim in g chain m ust be
inspected fo r w ear and replaced as
necessary. W ith new parts the maximum
deflection m ust not exceed 12.7 mm
(0.500 inch).
Injection pump gear.
Cam shaft gear.
Cam shaft sprocket with tim ing chain.
Crankshaft sprocket.

Figure 16Tim ing Chain and Sprockets
Tighten
Injection pump gear and bolts. Align the tim ing
marks (figure 15).
1. Crankshaft sprocket.
2. Camshaft sprocket with tim ing chain.
Im portant

Cam shaft gear, bolt, and washer.
Tighten
^X
Injection pump gear bolts to 23 N m (17 ft.

lbs.).
Bolt to 100 N m (75 ft. lbs.)

Injection pump gear and bolts.
Im portant
Measure
Clearance between injection pump gear and
baffle (figure 14). It is necessary to maintain a
minimum of 1.0 mm (0.040-inch) between the
gear and baffle, or noise may result.
6. Fuel return line boits.
6B).
grade of coolant.
TIMING CHAIN AND SPROCKET

REPLACEMENT
Measure
Tim ing chain free play as follows:
Mount a dial indicator to the front of the
block.
Position the dial indicator so that the
p lu n g e r c o n ta c ts th e tim in g c h a in
between the two gears.
Pull the chain outward (parallel to the
front face of the block) the maximum
am o un t w ith fin g e r p ressure on the
inside of the chain.
Set the dial indicator to zero.
Tighten
Tighten

Adjust
Injection pump tim ing, if new gears, sprockets, or
tim ing chain were installed. Refer to DIESEL FUEL
INJECTION (SEC. 6C2).
R AND V MODELS

1. Battery cables.
2. R adiator, shrouds, and fan. R efer to ENG INE
COOLING (SEC. 6B).
3. Vacuum pump. Refer to VACUUM PUMP (SEC. 6H).
4. P o w e r s te e rin g p u m p , g e n e ra to r, a nd a ir
conditioning compressor and position aside.
6. Rocker arm assemblies and pushrods, as outlined
previously.
Im portant
m arked for p ro pe r assem bly, as o u tlin e d
previously.
6.2 L DIESEL 6A6-15

Tighten
Lower the engine.
100
NOTICE: See N o tic e on page 6A6-1 o f this

section.
102
100.
101.
102.
103.
104.
B o lt
T h ru s t Plate
Key
S p a ce r
C a m s h a ft B-08036
4. Engine m ounting through bolts and nuts.

and 35.
5. Tim ing chain and sprockets, as outlined previously.
Im portant
Figure 17Camshaft and Components

7. Hydraulic lifters, as outlined previously. Place the
lifters in an organizer rack. The lifters must be
installed in the same bore from which they were
removed.
9. Tim ing chain and cam shaft sprocket, as outlined
previously.
10. Fuel pump (lift pump).
Raise the engine and block in position.
12. A ir co n d itio n in g co n d e n so r m ou ntin g bolts (if
equipped). Lift the condensor with the aid of an
assistant.
13. Bolts and thrust plate.
14. Camshaft. Pull the cam shaft from the block carefully
to avoid damage to the camshaft bearings.
15. Spacer (if necessary).

manual.
The u nit re p air m anual also d e scrib e s ca m sh aft
Install or Connect (Figures 16, 17, 34 and 35).

When a new camshaft is installed, replacement of
all hydraulic lifters, engine oil, and oil filte r is
recommended.
1. Spacer, with the ID cham fer towards the camshaft.
2. Camshaft.
Coat the camshaft lobes with Molykote or
equivalent.
Lubricate the cam shaft bearing journals with
engine oil.
Insert the cam shaft carefully into the block to
avoid damage to the camshaft-bearings.
3. Thrust plate and bolts.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Air conditioning condensor (if equipped).
Fuel pump (lift pump).
Hydraulic lifters, as outlined previously. Used lifters
must be installed in the same bore from which they
were removed.
Rocker arm a ssem blies and pushrods, in th e ir
original locations, as outlined previously. Hardened
ends of the pushrods must face up.
P o w e r s te e r in g p u m p , g e n e ra to r, a n d a ir
conditioning compressor, as equipped.
Vacuum pump. Refer to VACUUM PUMP (SEC. 6H).
Fan, radiator, and ra d ia to r sh ro u d s. R efer to
ENGINE COOLING (SEC. 6B).
Battery cables.
grade of coolant.
G MODELS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Battery cables.
Headlight bezels.
Grille, bumper, and lower valence panel.
Hood latch.
Coolant recovery bottle.
Upper tie bar.
A ir c o n d itio n in g c o m p re s s o r. R e fe r to A IR
R adiator and fan. Refer to ENG INE CO O LING
(SEC. 6B).
Oil pump drive, as outlined previously.
Cylinder heads, as outlined previously.
Generator lower bracket.
Water pump. Refer to ENGINE COOLING (SEC.
6B).
Fuel pum p (lift pump).
Rocker arm assemblies and pushrods, as outlined
previously.
6A6-16 6.2 L DIESEL

;
18.
19.
20.
21.
22.
Important

m arked fo r p ro pe r assem bly, as o u tlin e d
previously.
Hydraulic lifters, as outlined previously. Place the
lifters in an organizer rack. The lifters must be
installed in the same bore from which they were
removed.
Timing chain and camshaft sprocket, as outlined
previously.
Bolts and thrust plate.
Camshaft. Pull the cam shaft from the block carefully
to avoid damage to the camshaft bearings.
Spacer, if necessary.

manual.
The u nit re p air m anual also d e scrib e s ca m sh aft
Install or Connect (Figures 16 and 17).
When a new cam shaft is installed, replacement of

all hydraulic lifters, engine oil, and oil filte r is
recommended.
1. Spacer, with the ID cham fer towards the camshaft.
2. Camshaft.
Coat the cam shaft lobes with Molykote or
equivalent.
Lubricate the camshaft bearing journals with
engine oil.
Insert the cam shaft carefully into the block to
avoid dam age to the camshaft bearings.
3. Thrust plate and bolts.

4. Timing chain and camshaft sprocket, as outlined
previously.
5. Hydraulic lifters, as outlined previously. Used lifters
must be installed in the same bore from which they
were removed.
6. Rocker arm a ssem blies and pushrods, in th eir
original locations, as outlined previously. Hardened
ends of the pushrods must face up.
8. Fuel pump (lift pump).
6B).
12. Generator lower bracket.
13. Cylinder heads, as outlined previously.
14. Oil pump drive, as outlined previously.
15. R adiator and fan. R efer to ENGINE C OOLING
(SEC. 6B).
16. A ir c o n d itio n in g c o m p re s s o r. R e fe r to A IR
17. Upper tie bar.
18. Coolant recovery bottle.
19. Hood latch.
20.
21.
22.
Grille, bumper, and lower valence panel.

Headlight bezels.
Battery cables.
grade of coolant.
Evacuate and charge the air conditioning system (if
equipped). Refer to AIR CONDITIONING (SEC. 1B).
DIPSTICK TUBE REPLACEMENT

R AND V MODELS
1. Battery cables.
2. D ipstick tu be bracket, nut and washer, at the
exhaust manifold.
3. Dipstick tube.
4. O-ring from the dipstick tube.

1.
2.
3.
4.
New o-ring to the dipstick tube.

Dipstick tube to the engine.
Dipstick tube bracket nut and washer.
Battery cables.
G MODELS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery cables.
Engine cover.
Air cleaner.
Dipstick tube bracket, at the therm ostat housing.
D ipstick tube bracket, at the rocker arm cover
bracket.
stands.
Left exhaust manifold, as outlined previously.
Dipstick tube from the oil pan.
Lower the vehicle.
Dipstick tube from the vehicle.
O-ring.
6.2 L DIESEL 6A6-17
Figure 20Oil Pan and Oil Pump


1. New O-ring to the dipstick tube.
2. Dipstick tube to the vehicle.
Raise the vehicle. Support with suitable stands.
3. Dipstick tube to the oil pan.
4. Left exhaust manifold, as outlined previously.
4.
5.
6.
Lower the vehicle.

5. Dipstick tube bracket at the rocker arm cover.
6. Dipstick tube bracket at the therm ostat housing.
Clean
7. Air cleaner.
1. Old RTV from the oil pan and block.

2. All oil and grease from the gasket surfaces.
8. Engine cover.
9. Battery cables.
OIL PAN REPLACEMENT

(R AND V MODELS)
1. Battery cables.
stands.
2. Flywheel cover.
3. Left front engine m ounting through-bolt.
Raise the engine.

Oil pan bolts.
Oil pan.
Oil pan rear seal.

part num ber 1052915 or equivalent) to the oil pan
sealing surface, inboard of the bolt holes (figure 20).
The sealer must be wet to the touch when the oil
pan is installed.
1. Oil pan rear seal.
2. Oil pan to the engine. Be sure to connect the oil
dipstick.
3. Oil pan bolts.
&
Tighten
All except rear two bolts to 10.0 N-m (84 in.

lbs.).
Rear two bolts to 23 N-m (17 ft. lbs.).
6A6-18 6.2 L DIESEL

Lower the engine.
Let the oil pump and extension shaft fall into

the oil pan.
Remove the oil pan and oil pan rear seal.

section.
Tighten
5.
6.
7.

and 35.
Flywheel cover.
Lower the vehicle.
Proper quantity and grade of engine oil.
Battery cables.
1. Old RTV from the oil pan and block.

2. All oil and grease from the gasket surfaces.
I?
Inspect
Oil pump pick up tube and screen for damage.

Oil pump extension shaft bushing for cracks.
Oil Pump Repair

Refer to the proper unit repair manual,

(R AND V MODELS)
3. Oil pump and extension shaft.
I?
Inspect
Oil pump pick up tube and screen for damage.

Oil pump extension shaft bushing for cracks.

part num ber 1052915 or equivalent) to the oil pan
sealing surface, inboard of the bolt holes (figure 18).
The sealer must be wet to the touch when the oil
pan is installed.
1. Oil pan rear seal to the oil pan.
2. Oil pan and oil pump to the engine.
Lay the oil pump and extension shaft in the oil
pan.
Hold the oil pan and position the oil pump to
the main bearing cap.
Oil Pump Repair
Align the extension shaft hex with the drive

hex on the oil pump drive or vacuum pump.
The oil pump should push easily into place.
Install the oil pump bolt and tighten.

Oil pump and extension shaft to the engine. Align
the extension shaft hex with the drive hex on the oil
pump drive or vacuum pump. The oil pump should
push easily into place.
Oil pump bolt.
&
Position the oil pan against the engine. Be

sure to connect the dipstick tube.
3. Oil pan bolts.
&
Tighten
Oil pump bolt to 90 N m (65 ft. lbs.

OIL PAN AND OIL PUMP

REPLACEMENT (G MODELS)
1. Battery cables.
2.
3.
4.
5.
6.
7.
8.
9.
Engine cover.
Engine oil dipstick.
Engine oil dipstick tube at the rocker arm cover.
stands.
Transmission. Refer to TRANSMISSION (SEC. 7).
Engine oil cooler lines at the block.
Starter.
Oil pan bolts.
Oil pan and oil pump.
Lower the oil pan from the engine.
Rotate the crankshaft so that the forward
c ra n k s h a ft th ro w and n u m b e rs 1 and 2
connecting rod journals are up.
Oil pump to main bearing cap bolt.
4.
5.
6.
7.
8.
9.
Tighten
All except rear two oil pan bolts to 10.0 N m (84

in. lbs.).
Rear two oil pan bolts to 23 N m (17 ft. lbs.).
Starter.
Engine oil cooler lines.
Transmission. Refer to TRANSMISSION (SEC. 7).
Lower the vehicle.
Engine oil dipstick tube at the rocker arm cover.
Engine oil dipstick.
Engine cover.

11. Battery cables.

REPLACEMENT
The production rear crankshaft oil seal is a rope type
seal. The rope seal can be replaced with a two piece type
seal, if desired. Repair procedures for both types of seal
follow.
The CDR and crankcase ventilation system should be
thoroughly inspected and crankcase pressure should be
ch ecke d b efo re a new seal is in s ta lle d . R efer to
DRIVEABILITY AND EMISSIONS DIESEL (SEC. 6E9).
6.2 L DIESEL 6A6-19
A. C u t O ff S e c tio n O f O ld R ope Seal

B. Use B e a rin g C ap A s H o ld in g F ix tu re B-08041
Figure 22C utting the Rope Seal
A. U pper Seal G roove

B-08040
Figure 21Packing the Upper Rear

Crankshaft Rope Seal
ROPE TYPE SEAL
++
1. Oil pan and oil pump, as outlined previously.

2. Rear main bearing cap.
3. Old rope seal from the main bearing cap. Do not
discard.
Use J-33154-2 to work the short pieces of seal

cut previously onto the guide tool and into the
seal groove in the block (figure 23). It may help
to use engine oil on the seal pieces. The tools
have been machined to provide a built-in stop.
Use this procedure for both sides.
New rope seal to the main bearing cap.
Apply adhesive (GM part num ber 1052621
[Loctite 414] or equivalent) to the seal groove.
Position the rope seal on the bearing cap.
Use J-33153 to install the seal (figure 24).
A fter co rrectly p ositioning the seal, rotate
J-33153 slightly and cut the seal ends flush
with the bearing cap surface. Use a sharp tool
(figure 24).
Measure
Rear main bearing clearance, using plastic
gaging material. Refer to the proper unit repair
manual. If the clearance is out of specification,
Clean
Main bearing cap and block mating surfaces.
Rope seal groove in the main bearing cap.

Tools Required:
J-33154 Rear Oil Seal Packer
J-33153 Rear Oil Seal Installer
1. Rope seal pieces to the upper seal groove.

Use J-33154-2 and gently drive the upper seal
into the groove about 6 mm (1/4-inch). Do this
on both sides. Refer to figure 21.
Measure the amount the seal was driven up
on one side. Add 1.5 mm (Vis-inch). Cut this
length from the old seal removed from the
main bearing cap. Use the main bearing cap
as a holding fixture when cutting the seal
(figure 22). Use a sharp tool. Repeat this
procedure for the other side.
Install J-33154-1 onto the cylinder block (figure
23).
Figure 23Installing the Rope Seal Pieces

Rear Main Bearing Cap
6A6-20 6.2 L DIESEL

&
A. A p p ly A n a e ro b ic S e ale r
B. A fte r C o rre c tly P o s itio n in g
Seal, R o ta te Tool S lig h tly
A nd C ut O ff Each End O f
Seal F lu sh W ith Cap.
Tighten
Bolts to specifications, in the following

sequence:
Inner bolts: 150 N m (110 ft. lbs.).
Outer bolts: 135 N m (100 ft. lbs.).
Re-tighten all bolts in the same
sequence.
4. Oil pump and oil pan, as outlined previously.
J-33153
TWO PIECE TYPE SEAL

Oil pan and oil pump, as outlined previously.
Rear main bearing cap.
Upper and lower rope seal.
JH J|
B-08043
Figure 24Installing the Lower Rope Seal Piece
check the ends of the seal for fraying that may

prevent the main bearing cap from seating.
Correct as necessary. Remove the gaging
material from the bearing and journal.
NOTICE: The m ain bearing caps are to be
tapped into place with a brass or leather mallet
before the attaching bolts are installed. Do not
use the attaching bolts to pull the main bearing
caps into their seats, as this may damage the
bearing cap and/or block.
3. Main bearing cap to the block.
Apply a thin film of anaerobic sealant (GM part
num ber 1052756 or equivalent) to the bearing
cap as shown in figure 25. Keep the sealant off
the seal and bearing. Do not put sealant in the
bearing cap oil relief slot.
A p p ly a lig h t c o a t of e n g in e o il to th e
crankshaft surface that will contact the seal.
Apply engine oil to the main bearing cap bolt
threads.
Tap the main bearing cap into place with a
brass or leather mallet. Then install the bolts.
Clean
Upper and lower seal grooves and bearing cap slot
with a chlorinated solvent, such as carburetor spray
cleaner.
Main bearing cap and block mating surfaces.
Measure
Rear main bearing clearance, using plastic gage
material. Refer to the proper unit repair manual. If
the clearance is outside specifications, correct as
necessary.

1. Seal halves to the block (figure 26).
Apply a light coat of engine oil to the seal lips
where they contact the crankshaft.
R oll one seal half into the block seal groove
until 13 mm (1/2-inch) of the seals one end is
extending out of the block.
Insert the other seal half into the opposite side
of the seal groove in the block.
Important
The contact ends of the seal halves should
now be at the four and ten oclock positions, or
at the eight and two oclock positions. This is
necessary to align the rear main bearing cap
and seal lips.
N O T IC E : To p re v e n t d a m a g e to th e m ain
bearing caps, the caps are to be tapped into the
block using a brass or leather hammer. The new
seal is used as a guide. The cap must NOT be
pulled into the block with the bolts.
A. O il R e lie f S lo t
B. A p p ly A n a e ro b ic S e a le r to S haded A rea
F-02475
Figure 25Applying Sealer to the

Rear Main Bearing Cap
2. Main bearing cap to the block.

Lig htly coat the seal groove in the main
bearing cap with adhesive (GM part num ber
1052621 [Loctite 414] or equivalent).
num ber 1052756 or equivalent) to the main
bearing cap as shown in figure 25. Do not put
sealant in the oil relief slot.
threads.
6.2 L DIESEL 6A6-21
A. Use s h o rt p ie c e s o f 10 m m (3/s-inch) h o se to
p ro te c t th e c ra n k s h a ft jo u rn a l.
B-08045
INSTALLING THE UPPER SEAL HALF

Figure 27Replacing the Connecting Rod
and Piston
INSTALLING THE LOWER SEAL HALF
Figure 26Installing the Two Piece

Rear Crankshaft Seal

reamer.
cap for id e n tifica tio n marks. M ark the parts if
Attach two short pieces of 10 mm (3/s-inch)
hose to the connecting rod bolts (figure 27).
This will protect the crankshaft journal during
removal.
Push the connecting rod and piston out of the
bore.
Connecting rod bearings. Place the bearings in a
rack if they are to be reused, so they can be
returned to their original locations.

Main bearing cap bolts to specifications,
in the following sequence:
Re-tighten all bolts using the same
sequence.
3. Oil pump and oil pan, as outlined previously.
CONNECTING ROD AND PISTON

REPLACEMENT
++
1.
2.
3.
4.

C ylinder head, as outlined previously.
bores.

piston clearance, ring clearances, e tc Refer to the proper
unit repair manual.
Piston rings.
Cylinder bores.

Tool Required:
cylinder. Install new pistons in the cylinders for
which they were fitted. Install used pistons in the
cylinder from which they were removed.
6A6-22 6.2 L DIESEL
Figure 28Ring Gap Location
Figure 29Installing the Piston and

Connecting Rod
Be certain that the bearings are the proper

size.
connecting rod cap.

2. Piston and connecting rod to the proper bore.

two short pieces of 10 mm (3/e-inch) hose onto
the connecting rod studs.
engine oil.
The piston m ust be installed so that
depression in the piston crown is towards
outside of the engine. The connecting
b ea rin g ta ng slots m ust be o pp osite
camshaft.
Measure
the
the
rod
the
Tighten
Connecting rod cap nuts to 65 N m (48 ft. lbs.
Measure
g a g e b e tw e e n th e c o n n e c tin g rod and
crankshaft (figure 30). The correct clearance is
0.17-0.63 mm.
Place the piston in its m atching bore. Using

connecting rod to the crankpin with the pieces
of hose (figure 27). Hold the ring compressor
against the block until all rings have entered
the cylinder bore.
Remove the hoses from the connecting rod

bolts.
4. Main bearing caps.

Tool Required:
1. Glow plugs.
6.2 L DIESEL 6A6-23
Q
B-04580
Figure 30Checking Connecting Rod Side

Clearance
caps m ust be re tu rn e d to th e ir o rig in a l
5. Lower main bearing inserts from the main bearing
cafes.
6. Rear crankshaft oil seal, if necessary, as outlined
previously.
(figure 31).
Rotate the crankshaft to tu rn the bearing
-- Install or Connect (Figures 26, 31 and 32)

Tool Required:

required. Refer to the proper unit repair manual. The unit
repair manual contains information on

Crankshaft.

the block.
Remove the tool.
caps.
Measure
Main bearing clearance. Refer to the proper
unit repair manual. If the engine is in the
vehicle, the crankshaft m ust be supported
upward to remove any clearance from the
upper bearing. The total clearance can then
be measured between the lower bearing and
journal.
3. Rear crankshaft oil seal (if necessary) as outlined
previously.
6A6-24 6.2 L DIESEL

NOTICE: The main bearing caps are to be
tapped into place with a brass or leather mallet
before the attaching bolts are installed. Do not
use the attaching bolts to pull the main bearing
caps into their seats, as this may damage the
bearing cap and/or block.
4. Number 5 (rear) main bearing cap.
num ber 1052756 or equivalent) to the bearing
cap as shown in figure 25. Keep the sealant off
the seal and bearing. Do not put sealant in the
bearing cap oil relief slot.
A p p ly a lig h t c o a t of e n g in e o il to th e
crankshaft surface that will contact the seal.
threads.
REMOVAL

Bolts to specifications, in the following

sequence:
Re-tighten all bolts in the same
sequence.
5. Numbers 1, 2, and 4 main bearing caps and bolts.
Tighten
Bolts to specifications. Refer to step 46. Number 3 (center) main bearing cap and bolts.
Tighten the bolts tem porarily to 14 N m (10 ft. lbs.).
INSTALLATION
Measure
Tap th e end of th e c ra n k s h a ft firs t
re a rw a rd th e n fo rw a rd w ith a lead
bearing and crankshaft tnrust surfaces.
to specifications. Refer to step 4.
W ith the cra n ksh a ft forced forw ard,
measure at the front end of the num ber 3
main bearing with a feeler gage (figure
32). The proper clearance is 0.10-0.25
mm.
F-02474
Figure 33Replacing the Oil Filter Bypass Valve
OIL FILTER BYPASS

VALVE REPLACEMENT
1. Oil filter.
2. Oil filter bypass valve. Pry out with a screwdriver.
jiS Clean
Recess in the block.

9. Glow plugs.

1. Oil filter bypass valve. Tap into place, using a 16 mm
socket.
2. Oil filter.

3. Engine oil, as required.
6.2 L DIESEL 6A6-25

ENGINE MOUNTINGS
m o u n tin g breakag e o ccu rs, the re m ain in g
stresses.

may cuase it to be bent against the pum p
1. R aise the e n g in e to rem ove w e ig h t from the
m ountings and to place a slight tension on the
rubber cushion. Observe both m ountings w hile
raiding the engine.
exist:
cracks.
plate of the mounting.
and tighten the bolts or nuts attaching the mounting
Rear Mountings
Observe the transm ission m ounting.
exist:
M ou ntin g bottom ed o ut (ta ilsh a ft can be
b o lts or n u ts a tta c h in g th e m o u n tin g to th e

Raise the engine only enough to perm it removal of

-H - Install or Connect (Figures 34 through 37)
1. Engine m ounting assembly to the vehicle.
On V, G, and P models, the through-bolt must
be inserted from the rear of the right side
m ounting before the mounting is installed in
the vehicle.
section.
Tighten
through 37.
On V, G, and P models (right side), make sure there
is 25 mm (1 inch) clearance between the through
bolt head and mounting assembly.
Lower the engine until the through bolts can be
inserted.
section.
3. Through bolts and nuts.

through 37.

(EXCEPT P MODEL FLYWHEEL
HOUSING MOUNTING)
the oil pum p screen, resulting in a dam aged oil
pickup unit.
Support the rear of the engine to relieve the weight
on the rear mountings.
3. Mounting.

1. Mounting.
section.
6A6-26 6.2 L DIESEL
A. F orw ard
B. 40 N m (30 Ft. Lbs.)
C. T orque B o lt To 115 N m (85 Ft. Lbs.) Or, Torque N u t
To 75 N m (55 Ft. Lbs.)
D. 48 N m (36 Ft. Lbs.)
E. T orque B o lt To 48 N m (36 Ft. Lbs.) Or, T orque N u t To 40 N m (30 Ft. Lbs.)
B-08048
Figure 34Front Engine Mountings (R Models)
6.2 L DIESEL 6A6-27
A. Forw ard
B. 40 N m (30 Ft. Lbs.)
C. .Torque B o lt To 115 N m (85 Ft. Lbs.) Or, Torque N ut
To 75 N m (55 Ft. Lbs.)
D. 48 N m (36 Ft. Lbs.)
150. T ra n s m is s io n S tru t B ra cke t (A u to m a tic T ra n s m is s io n ) O r S p a c e r (M a nu al T ra n s m is s io n )
B-08049
Figure 35Front Engine Mountings (V Models)
B. Torque
Torque
C. 48 N m
D. Torque
Torque
B o lt to 100 N m (75 ft. lbs.) o r

N u t to 68 N m (50 ft. lbs.)
(36 ft. lbs.)
B o lt to 54 N m (40 ft. lbs.) o r
N u t to 40 N m (30 ft. lbs.)
E. 40 N-m
150. S p a ce r
Pum p B ra c k e t (L e ft S ide O nly)
Figure 36Front Engine Mountings (G Models)
F-02410
6A6-28 6.2 L DIESEL
A. F ro n t
B. T ig h te n B o lt to 115 N-m (85 Ft. Lbs.) or,
T ig h te n N u t to 75 N-m (55 Ft. Lbs.).
C. 48 N-m (36 Ft. Lbs.).
D. 40 N-m (30 Ft. Lbs.).

B-08050
Figure 37Front Engine Mountings (P Models)

Tighten
through 41.

(P MODELS FLYWHEEL HOUSING MOUNTING)
may cause it to be b ent against the pum p
2. Engine mounting.

1. Engine m ounting. Align the hole in the m ounting
with the hole in the crossmember.
Lower the engine.
section.
Tighten
ENGINE REPLACEMENT
R AND V MODELS
+ Remove or Disconnect
1. Battery cables.
stands.
6.2 L DIESEL 6A6-29
MODELS WITH THM 400 TRANSMISSION (RPO M40)

A. Forw ard
B. 48 N m (36 Ft. Lbs.)
B-07921
Figure 38Rear Engine Mountings (R Models)
6A6-30 6.2 L DIESEL
A. 54 N-m (40 Ft. Lbs.)

B. 48 N-m (36 Ft. Lbs.)
C. Forw ard
B
B-07897
2. Flywheel cover.
3. Flyw heel to torque co n v e rte r bolts (autom atic
transmission).
5. Starter.
6. Bell housing bolts.
7. Front engine mounting through-bolts.
8. Block heater.
9. W iring harness, transmission cooler lines, and front
battery cable clamp at the oil pan.
10. Fuel return lines at the engine.
11. Oil cooler lines at the engine.
12. Lower fan shroud bolts.
Lower the vehicle.
13. Hood.
14. Air cleaner with resonator.
15. Fuel filter.
16. Ground cable at the generator bracket.
17. Generator wires and clips.
18. W iring at the injection pump.
19. W iring from rocker arm clips, including glow plug
wires.
20. EGR-EPR solenoids, glow plug c o n tro lle r and
temperature sensor. Move the harness aside.
21. Left side ground strap.
22. Fan.
23. Fan shroud.
24. Power steering pump and reservoir and lay aside.
25. Vacuum hose at the cruise control transducer (if
equipped).
26. Accelerator, detent, and cruise control cables at the
injection pump.
27. Heater hose at the engine.
28. Radiator. Refer to ENGINE COOLING (SEC. 6B).
Support the transmission with a suitable jack.
29. Engine.
0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Figure 40Rear Engine Mountings (G Models)
18.
19.
20.

Engine to the vehicle.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Heater hose.
Accelerator, detent, and cruise control cables.
Vacuum hose at the transducer.
Power steering pump and reservoir.
Fan shroud.
Fan.
Left side ground strap.
EGR-EPR, glow plug controller, and temperature
sensor.
W iring at the rocker arm clips, including glow plug
wires.
Injection pump wiring.
Generator wires and clips.
Ground cable at the generator bracket.
Fuel filter.
Air cleaner and resonator.
Hood.
stands.
Lower fan shroud bolts.
Oil cooler and fuel return lines.
W iring harness, transm ission cooler lines, and front
battery cable clamp at the oil pan.
6.2 L DIESEL 6A6-31
MODELS WITH PROPSHAFT PARKING BRAKE
A.
B.
C.
D.
F orw ard
68 N m (50 ft. lbs.)
48 N m (36 ft. lbs.)
60 N m (44 ft. lbs.)
MODELS WITHOUT PROPSHAFT PARKING BRAKE

Figure 41 Rear Engine Mountings (P ModelsTransmission Tail Type Mountings)
B-07901
6A6-32 6.2 L DIESEL
Figure 42Rear Enging M ountings (P Models

Flywheel Housing Type Mounting)
21. Block heater.
NOTICE: See N o tic e on page 6A6-1 of this
section.
22. Engine m ounting through bolts.
Tighten
23.
24.
25.
26.
27.
28.

and 35.
Bell housing bolts.
Starter.
Exhaust pipes.
Flyw heel to to rq ue co nve rte r bolts (au tom a tic
transmission).
Flywheel cover.
Lower the vehicle.
Battery cables.
grade of coolant.
G MODELS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Tool Required:
J-33888 Lifting Fixture
Battery cables.
Headlight bezels, grille, bumper, and lower valence
panel.
Hood latch.
Coolant recovery bottle.
Upper fan shroud.
Upper tie bar.
Engine cover.
Condenser (vehicles with air conditioning). Refer to
R adiator and fan. Refer to ENGINE COOLING
(SEC. 6B).
Injection pump. Refer to DIESEL FUEL INJECTION
(SEC. 6C2).
stands.

12. Flywheel cover.
13. F lyw heel to torque co n v e rte r bolts (au tom a tic
transmission).
14. Engine m ounting through bolts.
15. Block heater wires.
16. Bellhousing bolts.
17. Starter.
Lower the vehicle.
18. Cruise control transducer (if equipped).
21. Oil fill tube upper bracket.
22. Glow plug relay.
23. Oil pressure sender harness.
24. Air cleaner resonator and bracket.
25. Transmission dipstick tube and move aside.
28. Water crossover/thermostat assembly.
29. Fuel lines at the fuel pump (lift pump).
30. Engine
Attach J-33888 to the center intake manifold
bolt holes. The two pieces of the tool should
extend down into the valley between the
cylinders.
Support the transmission.
Use a suitable lifting device to remove the
engines.

J-33888, and lifting device.
Transmission support.
2. Fuel lines to the fuel pump (lift pump).
3. Water crossover/therm ostat assembly, Use new
gaskets.
Tighten
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Heater hoses.
Oil pressure sender harness.
Glow plug relay.
Oil fill tube upper bracket.
Air conditioning compressor (if equipped). Refer to
Cruise control transducer (if equipped).
stands.
Starter.
Bellhousing bolts.
Block heater wires.

section.
17. Engine mounting through bolts.
6.2 L DIESEL 6A6-33

Tighten
18.
19.
20.
21.
22.
Fasteners to specifications. (Refer to figure

36).
F lyw heel to to rq ue co n ve rte r bolts (au tom a tic
transmission).
Flywheel cover.
Exhaust pipes.
Lower the vehicle.
Injection pump. Refer to DIESEL FUEL INJECTION
(SEC. 6C2).
R adiator and fan. Refer to ENGINE COOLING
(SEC. 6B).
23. C o n d e n s e r ( if e q u ip p e d ).
R e fe r to A IR
26. Engine cover.
27. Upper tie bar.
29. Coolant recovery bottle.
30. Hood latch.
31; Lower valence panel, bumper, grille, and headlight
bezels.
32. Battery cables.
grade of coolant.
SPECIFICATIONS
Item
N-m
Intake M anifold Bolts

E xh au st M anifold Bolts
R ocker Arm Cover Bolts
R ocker Arm S haft Bolts
H ydrau lic Lifter G uide Plate C lam p Bolts
C ylin d e r Head Bolts R efer to Procedure
Oil P um p Drive C lam p Bolt
Torsional D am per Bolt
C ra nksh a ft Pulley Bolts
Front C over to B lock Bolts
O il Pan Bolts (all except rear tw o bolts)
(rear tw o bolts)
Front C over Baffle Bolts and N ut
Injection Pum p N uts
Injection Pum p G ear Bolts
C am sha ft G ear Bolt
C am sha ft T hru st Plate
O il P um p Bolt
M ain B earing C ap Bolts Inner
O uter
C on ne cting Rod C ap Nuts
G low Plugs
W ater C rossover/T herm ostat H ousing Bolts
Fuel Pum p to Block
Flyw heel Bolts
B ell H ousing Bolts
42
35
22
55
26
42
270
40
45
10.0
23
45
42
23
100
23
90
150
135
65
14
42
34
90
40
Ft. Lbs.
31
26
16
40
18
31
200
30
33
17
33
31
17
75
17
65
110
100
48
10
31
25
65
30
In. Lbs.
84
6A6-34 6.2 L DIESEL
All S pecifications are in m illim eters (mm) unless otherwise noted.
GENERAL DATA:
Type
90-degree V8 Diesel
D isplacem ent
6.2L
RPO
LH6 LL4
Bore
101
Stroke
97
C om pression Ratio
21.3:1
Firing O rder
1-8-7-2-6-5-4-3
Oil Pressure
10 psi at idle (hot); 4 0 -4 5 psi at 2000 RPM
CYLINDER BORE:
D iam eter
100.987-101.065
D iam eter
0.02 (M axim um )
Taper (Thrust Side)
0.02 (M axim um )
PISTON:
Bohn Pistons
C learance
Z o lln e r P istons*
Bores 1 through 6
0.089-0.115
Bores 7 and 8
0.102-0.128
Bores 1 th rough 6
0.112-0.138
Bores 7 and 8
0.125-0.151
PISTON RING:
G roove
C learance
C om pression
G ap
Top
0.076-0.178
2nd
0.75-1.00
Top
0.30-0.55
2nd
0.75-1.00
G roove C learance
Oil
G ap
0.040-0.096
0.25-0.51
PISTON PIN:
D iam eter
30.9961-31.0039
C learance
0.0081-0.0309
Fit in Rod
0.0081-0.0309
CRANKSHAFT
Main
Journal
D iam eter
#1, 2, 3, 4
74.917-74.941
#5
74.912-74.936
Taper
0.005 (M axim um )
O ut of Round
0.005 (M axim um )
Main Bearing
#1, 2, 3, 4
0.045-0.083
C learance
#5
0.055-0.093
C rankshaft End Play
0.10-0.25
D iam eter
C rankpin
60.913-60.939
Taper
0.005 (M axim um )
O ut-of-R ound
0.005 (M axim um )
Rod Bearing C learance

Rod Side C learance
*N o t used in production reference for service stock pistons only.
0.045-0.100
0.17-0.63
6.2 L DIESEL 6A6-35
All S pecifications are in m illim eters (mm) unless otherw ise noted.
DISPLACEMENT
6.2 L
CAM SHAFT:
Lobe LlTt 0.05
Jo urna l D iam eter
Intake
7.133
E xhaust
7.133
#1, 2, 3, 4
54.975-55.025
#5
50.975-51.025
Jo u rn a l C learance
0.026-0.101
C am sha ft End Play
0.051-0.305
VALVE SYSTEM:
H ydraulic R oller
Lifter
1.5 : 1
R ocker Arm Ratio

Intake
valve Lasn
E xhaust
N ot A d justa b le
Face A n gle (Intake & Exhaust)
45
S eat A ngle (Intake & Exhaust)
46
S eat R unout (Intake & E xhaust
0.05
S eat W idth
Stem C learance
Valve
Spring
Pressure
N ew tons @ mm
Intake
0.89-1.53
E xhaust
1.57-2.36
Intake
0.026-0.069
E xhaust
0.026-0.069
C losed
356 N @ 46.0 mm
O pen
1025 N @ 35.3 mm
46
Installed H eight
Mining w iiam i
iu c
r lay
New C hain
Used C hain
12.7 mm (0.500-inch)
20.3 mm (0.800-inch)
6A6-36 6.2 L DIESEL
SPECIAL TOOLS
1.
J-8037
7.
J-22102
2.
J-33154
8.
J-23523-E
3.
J-33153
9.
J-29664
4.
J-26513-A
5.
J-29666
10.
J-8080
6.
J-29834
11.
J-33888
1.
2.
3.
4.
5.
6.
R ing C o m p re s s o r
R ear O il Seal P acker
R ear O il Seal In s ta lle r
Valve S p rin g C o m p re s s o r
A ir L in e A d a p te r
H y d ra u lic L ifte r R em over
7.
8.
9.
10.
11.
Seal In s ta lle r
T orsion al D a m p e r R em ove r
M a n ifo ld C ove r Set
M ain B e aring R e p la c e r
E n g in e L iftin g F ix tu re (G M od els)
F-02409
6A7-1
SECTION 6A7
4.8 LITER L6
m anual as indicated at appropriate locations by the term inology See NOTICE on page 6A7-1 of this section.
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in m ajor repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacem ent becomes necessary. Torque values must be used as
specified during reassembly to assure proper retention of all parts.
CONTENTS
SUBJECT
PAGE
Description................................................................................................................................................................... 6A7- 2
Engine Lubrication...................................................................................................................................................6A7- 2
On-Vehicle S e rvice .....................................................................................................................................................6A7- 4
Rocker Arm Cover Replacem ent..........................................................................................................................6A7- 4
Rocker Arm and Pushrod Replacement............................................................................................................... 6A7- 4
Valve Adjustment.................................................................................................................................................... 6A7- 5
Valve Stem Seal And Valve Spring Replacement............................................................................................... 6A7- 5
Pushrod Cover R eplacem ent................................................................................................................................ 6A7- 6
Hydraulic Lifter Replacement................................................................................................................................ 6A7- 6
Intake And Exhaust Manifold Replacement......................................................................................................... 6A7- 7
Rocker Arm Stud R eplacem ent............................................................................................................................ 6A7- 8
Cylinder Head Replacement.................................................................................................................................. 6A7- 9
Torsional Damper And Front Crankshaft Seal Replacement............ ............................................................ 6A7-10
Timing Gear Cover Replacement..........................................................................................................................6A7-11
Oil Pan Replacement...............................................................................................................................................6A7-12
Oil Pump Replacement.......................................................................................................................................... 6A7-12
Rear Crankshaft Oil Seal Replacem ent................................................................................................................6A7-13
Checking Valve T im in g .......................................................................................................................................... 6A7-14
Measuring Camshaft Lobe L if t .............................................................................................................................. 6A7-14
Camshaft Replacement.......................................................................................................................................... 6A7-15
Connecting Rod And Piston R eplacem ent......................................................................................................... 6A7-16
Main Bearing Replacement.................................................................................................................................... 6A7-18
Crankshaft Gear Replacem ent.............................................................................................................................. 6A7-19
Oil Filter Bypass Valve Replacement....................................................................................................................6A7-20
Flywheel R eplacem ent.......................................................................................................................................... 6A7-20
Engine M o u n tin g s.................................................................................................................................................. 6A7-21
Engine Replacement.............................................................................................................................................. 6A7-24
S p e cifica tio n s.............................................................................................................................................................6A7-25
Special T o o ls ...............................................................................................................................................................6A7-28
6A7-2 4.8 LITER L6
DESCRIPTION
are a floating fit in the pistons.
ENGINE LUBRICATION
B-05053
Figure 1Lubrication Diagram (Side View)

4.8L engines are inline six cylinder type, overhead
valve, water cooled, with cast iron block and head.
The crankshaft is supported by seven precision insert
seven (rear) bearing.
The camshaft is supported by four plain type bearings
and is gear driven. Motion from the camshaft is transm it
ted to the valves by hydraulic lifters, pushrods, and balltype rocker arms. The valve guides are integral in the
cylinder head.
Lubrication schematics are shown in figures 1 and 2.

The gear type oil pump is driven through an extension
shaft from the distributor drive shaft, which is gear driven
from the camshaft. Oil is drawn into the oil pump through
a pickup screen and pipe.
excessive backpressure at the oil filter, a bypass valve is
provided. This valve will allow oil flow to the main oil
gallery at the right side of the block. This gallery supplies
oil to the camshaft bearings, hydraulic lifters, and main
bearings. The connecting rods are supplied oil from the
main bearings by means of drilled passages in the
crankshaft. The valve train is supplied with oil by the
hydraulic lifters. Oil is pumped from the lifters through the
hollow pushrods to the rocker arms. Oil drains back to the
crankcase through oil drain holes and the pushrod holes.
The piston, piston pin, and tim ing gears are lubricated by
oil splash.
4.8 LITER L6 6A7-3
A.
B.
C.
D.
E.
O il P re ssu re S e n d in g U n it
D is tr ib u to r S h a ft O ilin g
S p la s h O ilin g
F ilte r B yp a ss S y s te m
F u ll F lo w O il F ilte r
B-09222
Figure 2Lubrication Diagram (Front View)
6A7-4 4.8 LITER L6
ON-VEHICLE SERVICE:
3. Bolts, clips, and reinforcem ents.
Tighten
Bolts to 4.3 N-m (38 in. lbs.).
4. W iring, fuel and vacuum lines to the clips.
5. Air cleaner.
6. Crankcase ventilation hoses to the rocker arm cover.
ROCKER ARM AND

PUSHROD REPLACEMENT
1. R ocker arm cover, as o utline d previously.
2. R ocker arm nut.
pushrod out.
4. Pushrod.
1. C lip
2. B o lt
4. R o cke r A rm C over
5. G a ske t
Im portant
Figure 3Rocker Arm Cover Installation
ROCKER ARM COVER

REPLACEMENT
1. C rankcase ve ntilatio n hoses at the rocker arm
cover.
2. A ir cleaner.
3. W iring, fuel and vacuum lines from the clips.
4. Bolts, reinforcem ents, and clips.
If the rocker arm cover adheres to the cylinder
head, try to shear the gasket by bumping the
end of the cover with a rubber mallet. DO NOT
DISTORT THE SEALING FLANGE.
6. Gasket.
Clean
All traces of old gasket from the rocker arm cover
and cylind er head.
Inspect
Rocker arm cover sealing surfaces for distortion.
Straighten or replace as needed.
1. New gasket.
Store used com p on en ts in order so they can be

reassem bled in the sam e location.
B-07856
I*
Inspect
R ocker arm s and balls at th e ir m ating surfaces.
T hese surfaces should be sm ooth and free from
scoring or other dam age.
R ocker arm areas w hich co nta ct the valve stem s
and the sockets w h ich c o n ta c t th e pushrods.
T h e s e a re as s h o u ld be s m o o th and free of
dam age and wear.
P ushrods for bending. Roll the pushrod on a flat
s u rfa ce to d e te rm in e if it is bent. R ep lace if
necessary.
Ends of the pushrods fo r scoring or roughness.
Install or Connect
1. Pushrod. M ake sure the pushrod seats properly
in the hydraulic lifter.
2. R ocker arm w ith ball.
Im portant
W hen new rocker arm s a nd /or balls are
installed, coat th e ir bearing surfaces w ith
M olykote or e quivalent.
3. Rocker arm nut.
Adjust
Valves as outline d later.
4.8 LITER L6 6A7-5
20.
21.
22.
23.
Valve K e ep e r
R o ta to r
S h ie ld
O -R ing Seal
24.
25.
26.
27.
28.
Seal
D am per
S p rin g
In ta ke Valve
E x h a u s t Valve
B-07859
Figure 4Adjusting The Valves
Figure 5Valves And Components
VALVE ADJUSTMENT
VALVE STEM SEAL AND


2. Adjust the valves when the lifter is on the base circle
of the camshaft lobe as follows:
a. Mark the distributor housing with chalk, at #1
and #6 plug w ire p osition s. Rem ove the
distributor cap and lay aside.
b. Crank the engine until the distributor rotor
points to #1 cylinder position. The following
valves can be adjusted with the engine in the
#1 firing position:
#1 cylinder-E xhaust and Intake
#2 cylinder-lntake
#3 cylinder-E xhaust
#4 cylinder-lntake
c. Back out the adjusting nut until lash is felt at
the pushrod, then turn in the adjusting nut
u n til a ll la sh is re m o v e d . T h is can be
determ ined by rotating the pushrod w hile
turning the adjusting nut (figure 4). When play
has been removed, turn the adjusting nut in
one full additional turn (to center the lifter
plunger).
d. Crank the engine until the distributor rotor
points to #6 position. The following valves can
be adjusted w ith the e ng in e in #6 firin g
position:
#3 cylinder-lntake
#5 cylinder-lntake
#6 cylinder-lntake and Exhaust
3. Install the distributor cap.
4. Install the rocker arm cover as outlined previously.

Tools R equired:
Spark plugs.
Valve keepers (20).
place.
(figure 6).
J-5892-B.
6A7-6 4.8 LITER L6
Figure 7Testing The Valve Seals

5. Rotator (21), shield (22) and spring (26) with damper
(25).
6. O-ring seal (23).
7. Seal (24) (intake valve only).
|+<-| Install or Connect (Figures 5, 6, and 7)
1.
2.
3.
4.
5.
Tools R equired:
J-23738-A Vacuum Pump.
New seal (24) (intake valve only). Install the seal
over the valve stem and seat it against the head.
Spring (26) with the dam per (25), shield (22) and
rotator (21).
New O-ring seal (23) and valve keepers (20).
(figure 6).
Lubricate the o-ring seal with engine oil. Install
the seal on the valve stem. Make sure the seal
is not twisted.
them in place.
Check each o-ring seal for leakage (figure 7).
Connect J-23738-A to the suction cup
and apply a vacuum. Watch the vacuum
pump gage. No air should be able to
leak past the seal. If the seal will not hold
a vacuum, it may have been damaged or
improperly installed.
Spark plugs.
Adjust
Valves, as outline d previously.
PUSHROD COVER
REPLACEMENT
1. B attery negative cable.
2. D ipstick tube.
3. Distributor. Refer to E N G IN E E LE C TR IC A L (SEC.
6D).
4. Pushrod cover bolts.
5. Pushrod cover.
6. Gasket.
|mj| Clean
Old gasket from pushrod cover and block.
Install or Connect
1. Pushrod cover and new gasket.
2. Pushrod cover bolts.
Tighten
Pushrod cover bolts to 9.0 N m (80 in. lbs.).

6D).
4. Dipstick tube (if removed).
HYDRAULIC LIFTER
REPLACEMENT
Tools R equired:
J-3049 Hydraulic Lifter Remover (Plier Type) or
J-9290-01 Hydraulic Lifter Remover
(Slide Hammer Type)
1. Rocker arm cover, pushrod cover, and pushrod, as
4.8 LITER L6 6A7-7
32. C la m p
33. N u t
B-07861
Figure 10Manifold Installation

2. Pushrod cover, as outlined previously.
ft
Adjust
Valves, as o utline d previously.

B-05064
INTAKE AND EXHAUST

MANIFOLD REPLACEMENT
Figure 9Removing The Hydraulic Lifter

Remove the hydraulic lifters one at a tim e and
place them in an organizer rack. The lifters
must be installed in the same bore from which
they were removed.
J-3049 (figure 8 or J-9290-01 (figure 9).
H ydraulic lifter body for scu ffing and scoring. If

the lifte r body w all is w orn or dam ag ed , the
m ating bore in the block should also be checked.
C heck the fit of each hydraulic lifte r in its m ating
broe in the block. If the clearance is excessive, try
a new lifter.
The hydraulic lifter foot m ust be sm ooth and
slig h tly convex. If w orn, pitted, or dam aged, the
m ating ca m sh aft lobe should also be checked.
4-+ Remove or Disconnect (Figures 10 and 11)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Bolt (35) and nuts (40).
M anifolds (34 and 39).
G asket (38).

+4- Install or Connect
H ydraulic lifters to the block. Lubricate the lifter
foot and body w ith Engine Oil S u pp lem en t or
equivalent.
W hen any new hydraulic lifters or a new
c a m s h a ft is in s ta lle d , a ls o re p la c e th e
c ra n k c a s e o il and filte r. E n g in e O il
Supplement (or equivalent) should be added
to the crankcase oil.
R eplace all h yd ra u lic lifte rs w hen a new
B attery negative cable.

A ir cleaner.
T hrottle co ntrols at the bell crank.
C arburetor (if necessary).
Fuel and vacuum lines from the m anifold, EGR
valve (if used) and EFE valve.
AIR pum p and bracket.
PCV hose.
E xhaust pipe.
M anifold heat stove.
C lam ps (32), bolts (31), nuts (33) and w ashers.
M anifold assem bly and gasket.
ay
Clean
All m anifold bolts and studs. Then a pp ly e ngine
oil to the threads.
All traces of old gaskets from the c ylin d e r head
and m anifolds.
Inspect
M a n ifo ld s fo r c ra c k s o r d a m a g e to g a s k e t
surfaces.
O peration of EFE or m anifold heat valve (if used).
G askets, if n e c e ssa ry to d ia g n o se a leakage
problem .
6A7-8 4.8 LITER L6
A. N u t
B. F la t W a s h e r
B-05245
Figure 12Removing The Rocker Arm Stud

31.
32.
33.
34.
35.
B o lt
C la m p
N ut
E xh a u st M a n ifo ld
B o lt
Tighten
36.
37.
38.
39.
40.
W a sh er
S tu d
G a sket
In ta ke M a n ifo ld
N ut
B-07866
Figure 11Manifolds And Components
5.
6.
7.
8.
9.
Measure
M anifold d istortion. Lay a straight edge along the
full length of the m anifold exhaust port faces and
m easure any gaps betw een the straig ht edge and
the port faces. If at any point a gap of 0.80 mm
(0.030-inch) or m ore exists, it is likely th at the
m anifold has d istorted to a point w here it w ill not
seal properly. If a good exhaust seal is to be
e x p e c te d , th e e x h a u s t m a n ifo ld m u s t be
replaced.

1. G asket (38) to the exhaust m anifold (34).
2. Intake m anifold (39) to the exhaust m anifold.
3. Both (35), w ashers (36) and nuts (40). LEAVE
FING ER TIGHT.

1. New gasket, over th e m an ifold stu d s on the
cylin d e r head.
2. M anifold assem bly.
10.
11.
12.
13.
Bolts (31) and nuts (33) to 52 N-m (38 ft.

lbs.).
Bolts (35) and nuts (40) to 60 N-m (44 ft.
lbs.).
Manifold heat stove.
Exhaust pipe.
PCV hose.
AIR pump and bracket.
Fuel and vacuum lines from the manifold, EGR
valve (if used) and EFE valve (if used).
Carburetor (if removed).
Throttle controls.
Air cleaner.
Adjust
Engine idle speed, if necessary.
ROCKER ARM STUD

REPLACEMENT
Tool R equired:
J-5802-01 Rocker Arm Stud Remover
previously.
2. Rocker arm stud.
H" Install or Connect (Figures 13 and 14)
3. C lam ps (32).
4. Bolts (31), and nuts (33).
Im portant
Alw ays tig hte n the m anifold to cylind er head
b o lts a n d n u ts (31 a n d 3 3 ) B E F O R E
tig hte nin g the m anifold center bolt and nuts
(35 and 40).
Tools R equired:
J-5715 Reamer (0.003-inch oversize) or
J-6036 Reamer (0.013-inch oversize)
J-6880 Rocker Arm Stud Installer
rocker arm stud without reaming stud hole as
this could damage the cylinder head.
4.8 LITER L6 6A7-9
FRONT OF ENGINE
B-05258
Figure 15Cylinder Head Bolt

Tightening Sequence
Adjust
R ea m th e h o le to th e p ro p e r s iz e fo r th e
replacement oversize rocker arm stud. Use J-5715
for 0.003-inch oversize studs; J-6036 for 0.013-inch
oversize stud (figure 13).
CYLINDER HEAD
REPLACEMENT
Coat lower end (press-fit area) of the rocker arm

stud with hypoid axle lubricant.
installed to proper depth when the tool bottoms on
the cylinder head.
8.
9.
10.
11.
IJjl

M anifold assem bly, as outlined previously.
AIR ch eck valve.
R ocker arm cover, as outlined previously.
Pushrods. Back o ff th e rocker arm nuts. Turn the
rocker arm s aside, then rem ove the pushrods.
Place the push ro ds in a rack so th ey can be
returned to th e ir o rigin al locations at assem bly.
S park plug w ires at the spark plugs.
Vacuum lines at the th erm al vacuum sw itch on
the w ater outlet.
Drain the radiator and block.
U pp er ra d ia to r hose, h eater hose, and w ater
pum p bypass hose.
B attery ground strap at the cylind er head.
C ylin de r head bolts.
C ylin de r head and gasket.
Clean
C arbon deposits from co m b ustio n cham bers.
All traces of old head gasket from cylin d e r head
and block.
C ylin de r head bolt th re ad s and th re ad s in the
block.
I?
Inspect
S ealing su rfa ces of the block and c y lin d e r head

for nicks, heavy scratches, or other dam age.


1. Head gasket.
even.
6A7-10 4.8 LITER L6
F-02325
Figure 17Installing The Timing Gear

Cover And Seal
B-01325
Figure 16Removing The Torsional Damper

2. Radiator. Refer to ENGINE COOLING (SEC. 6B).
3. Drive belts from the crankshaft pulley.
Do n ot use s e a le r on c o m p o s itio n
steel-asbestos gaskets.
Place the gasket over the block dowel pins
with the bead up.
2. C ylinder head. Carefully guide the cylinder head
into place over the dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound and install finger
tight.
Tighten
C ylin de r head bolts, a little at a tim e, using

the sequ en ce show n in figure 15, until the
specified to rq ue is reached.
Left hand front bolt: 115 N-m (85 ft. lbs.).
All other bolts: 130 N-m (95 ft. lbs.).
Battery ground strap at the cylinder head.
Upper radiator hose, heater hose, and water pump
bypass hose. Fill the cooling system with the proper
coolant.
Vacuum lines at the thermal vacuum switch.
Spark plug wires.
Pushrods. Be sure to install them in their original
locations.
Rocker arms to the pushrods.

5. Torsional damper. Use J-23523-E (figure 16).
6. F ro n t c ra n k s h a ft s e a l. P ry o u t w ith a la rg e
screwdriver. Take care not to distort the tim ing gear
cover.
Inspect
Oil seal co nta ct area on the torsional d am pe r for
grooving and roughness. R eplace if necessary.

Tools R equired:
J -2 3 5 2 3 -E T o rsio n a l D a m p e r P u lle r and
Installer
J-35468 Centering Tool and Seal Installer
1. Front crankshaft seal. Use J-35468 (figure 17). Coat
the seal lips with engine oil. The open end of the
seal faces inside the engine.
Adjust

11. AIR check valve.
12. Manifold assembly, as outlined previously.

REPLACEMENT
Tool R equired:
J -2 3 5 2 3 -E T orsion al D a m p e r P u lle r and
Installer.
A. Bearing
B. W asher
C. Stud
D. N ut
B-05254
Figure 18Installing The Torsional Damper
4.8 LITER L6 6A7-11

NOTICE: The in ertia w eig h t section o f the
follow ed or m ovem ent o f the inertia weight
section of the hub will destroy the turning of
the torsional damper.
2. Crankshaft key (if removed).
3. Stud (item C, figure 18) to the crankshaft. Thread the
stud fully into the tapped end of the crankshaft.
4. Torsional damper over the end of the stud. Align the
keyway in the torsional dam per shaft w ith the
crankshaft key.
5. Bearing, washer, and nut (figure 18).
Turn the nut to pull the torsional dam per into
place.
Remove the tool.
Torsional d am pe r bolt to 70 N m (50 ft. lbs.).

Drive belts to the crankshaft pulley, and tension to
specifications.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Fill the cooling system with the proper coolant.
Cut the tabs from a new seal as shown in

figure 20. Use a sharp cutting tool to help
make a clean, straight cut.
Position the seal against the cover. Press the
retaining tips into the holes in the cover.
3. Timing gear cover to block gasket to the tim ing gear
cover. Use gasket sealer to hold it in place.
Apply a 3 mm (Vs-inch) bead of RTV sealant to the
joint formed at the oil pan and cylinder block.
4. Timing gear cover, with J-35468 in place, to the
block (figure 17).
Im portant
TIMING GEAR COVER

REPLACEMENT
1.
2.
3.
4.
5.
B attery negative cable.

Torsional damper, as described previously.
Oil pan to tim ing gear cover bolts.
T im in g gear cover to block bolts.
T im in g gear cover.
Pull the cover slightly forward only enough to
permit cutting of the oil pan front seal.
Using a sharp knife or other suitable cutting
tool, cut the oil pan front seal flush with the
block at both sides of the oil pan.
Remove the cover and attached portion of the
oil pan front seal.
6. Timing gear cover gasket.
7. Front crankshaft seal. Pry out with a screwdriver. Be
careful not to distort the tim ing gear cover.
The tool is used to align the tim in g gear

cover so th a t the front cran ksha ft seal is
p roperly centered around the crankshaft.
T h e s e a l m u s t be c e n te re d to p re v e n t
dam age d u rin g hub installation.
5. Oil pan to tim ing gear cover bolts. Partially tighten
the bolts.
6. Timing gear cover to block bolts.
Tighten
T im in g gear cover to block bolts to 9.0 N m
(80 in. lbs.).
Oil pan to tim in g gear cover bolts to 5.1 N m
(45 in. lbs.).
++
J-35468 from the tim in g gear cover.

Clean
O ld gasket from the tim in g gear cover, block, and
oil pan.
-+ Install or Connect (Figures 17, 19, and 20)

Tool R equired:
J-35468 Centering Tool and Seal Installer
1. Front crankshaft to the timing gear cover.
Lubricate the seal lips with engine oil.
Use J-35468 to press the seal into place
(figure 19).
Leave the tool in position in the seal.
2. Timing gear cover to oil pan seal.
A. C ut T h is P o rtio n F rom N ew Seal

B-07870
Figure 20Front Oil Pan Seal Modification
6A7-12 4.8 LITER L6

OIL PAN REPLACEMENT
++

2. Starter.
3. Torque converter or flyw heel cover.
4. Front engine m ou nt through-bolts.
Raise the e ngine and block in position.
5. Oil pan bolts.
6. Oil pan.
7. Old gaskets and seals.
Old gasket and seals from the block and oil pan
sealing surfaces.
Install or Connect
Oil Pump Repair

1. New rear oil pan seal to the rear m ain bearing

cap.
Install or Connect
3. New oil pan to b lock gaskets to the block. Use

gasket ce m e nt to hold them in place.
1. Oil pum p to the engine. A lign the slot in the oil

pum p sh aft w ith the tang on th e d istrib u to r shaft.
The oil pum p should slide easily into place. No
gasket is used.
4. Oil pan bolts.
2. Oil pum p bolts.
2. New front oil pan seal to the tim in g gear cover.

Press the retaining tip s into the holes in the cover.
Tighten
1/4-inch oil pan to block bolts to 9.0 N m (80
in. lbs.).
5/ie -inch oil pan to block bolts to 18.6 N m
(165 in. lbs.).
Oil pan to tim in g gear cover to 5.1 N m (45
in. lbs.).
Oil pum p bolts to 13.0 N m (115 in. lbs.).

3. Oil pump pickup tube bracket to main bearing cap
nut.

4. Oil pan, as outline d previously.
Lower the engine.

5. Front engine mount through-bolts.
REAR CRANKSHAFT OIL

SEAL REPLACEMENT
6. Torque converter or flywheel cover.

7. Starter.

1. Oil pan, as outline d previously.
2. Oil pum p p icku p tube bracket to m ain bearing
cap nut.
3. Oil pum p bolts.
4. Oil pump.
I*
Inspect
Oil pum p picku p tube for looseness. If the tube is
loose in the oil pum p body, replace it, as outlined
in the proper unit repair m anual. A loose pickup
tube can result in an air leak and loss of oil
pressure.
The rear main bearing oil seal can be replaced (both

halves) w ithout removal of the crankshaft. Always replace
the upper and lower seal as a unit. Install the seal with the
lip facing the front of the engine. Extreme care should be
exercised when installing this seal to protect the sealing
bead located in the channel on the outside diameter of
the seal. An installation tool (figure 23) should be used to
protect the seal bead when positioning the seal. (Some
seal kits include the tool as part of the service kit).
4- +

2. R ear m ain bearing cap.
3. Lower seal half (figure 21).
4. U pper seal half (figure 22).
Tap on the upper seal half, using a small drift
and hammer.
Remove the upper seal half, using pliers.
4.8 LITER L6 6A7-13
B-03487
Figure 22Removing The Upper Seal Half

Clean
Sealing surfaces of the m ain bearing cap and
block.
Inspect
C rankshaft, seal ch an ne l, and sealing surfaces
fo r nicks, scratches, etc.
+- Install or Connect (Figures 23, 24, and 25)
A.
B.
C.
80.
81.
82.
83.
84.
F orw ard
F a b ric a te d Tool
O il Seal Lip
U p p e r Seal H a lf
C ra n k s h a ft
B lo c k
L o w e r Seal H a lf
M ain B e a rin g Cap
B-07871
Figure 24Installing The Rear Crankshaft

Oil Seal
U pper seal half.
Important
An oil seal installation tool (figure 23)
should be fabricated (if not provided in
the seal kit) to prevent seal dam age
A. 4 m m (11/64-inch)
B. 13 m m (1/ 2 -in ch)
C. 0.10 m m (0.004-inch) s h im s to c k
Apply Sealant to Shaded Areas Only 0 .9 3 4 9 8

B-05250
Figure 25Applying Sealant To The Block

Figure 23Oil Seal Installation Tool
6A7-14 4.8 LITER L6

during installation. Extreme care should
be taken when installing this seal to
protect the sealing bead located in the
channel on the outside diameter of the
seal.
P osition th e tip of th e to ol betw een the
crankshaft and the seal seat in the block
(figure 24).
Position the seal half between the crankshaft
and the tip of the tool. Make sure that the oil
seal lip is positioned toward the front of the
engine.
Roll the seal around the crankshaft using the
tool as a shoe-horn to protect the seal bead
from the sharp corner of the seal seat surface
in the block. The installation tool must remain
in position until the seal half is properly
positioned with both ends flush with the block.
Remove the tool, being careful not to withdraw
the seal half.
2. Lower seal half.
Insert the seal half into the rear main bearing
cap. Use the tool to protect the seal half from
the sharp edge of the seal seal. Feed the seal
half into the rear main bearing cap, using light
finger pressure. Make sure the oil seal lip
faces the front of the engine (figure 24).
3. Rear main bearing cap with the lower main bearing.
25). Do not a llo w any se a la n t on e ith e r
Apply engine oil to the lower main bearing.
Position the cap to the block. Install the cap
bolts.
Tighten
Rear main bearing cap bolts temporarily
to 14 N m (10 ft. lbs.).
then forward with a lead hammer. This will line
up the rear main bearing and crankshaft thrust
surfaces.
J-8520
B-03714
Figure 26Checking Valve Timing Or

Camshaft Lobe Lift
2. Install a dial indicator, along with J-8520 (figure 26).
Turn the crankshaft until the #2 exhaust valve opens
and the notch on the dam per is aligned with the 0
mark on the tim ing tab.
3. P o s itio n th e d ia l in d ic a to r to m e a s u re lifte r
m ovem ent and set ind ica to r at zero. Turn the
crankshaft 360 degrees and read the indicator. On
co rrectly tim ed engines the ind icato r w ill read
0.012-0.020-inch.
4. If the reading is not as shown, reset the indicator at
zero and turn the crankshaft 360 degrees, then read
the in d ic a to r again. If rea din g is now w ith in g
specifications, the engine is tim ed properly.
5. The chart following shows indicator readings with
gears properly indexed for 4.8L engines and the
indicator readings resulting from im properly indexed
gears.
Engine
Camshaft
Valve Lift
Dial
Indicator
Readings
Part Number
4.8L
3848000
0.405
Gears Properly Indexed

One Tooth Advanced
One Tooth Retarded
0.012-0.020
0.038
0.007
Tighten
Rear main bearing cap bolts to 90 N-m
(65 ft. lbs.).
5. The proper quantity and grade of engine oil.
CHECKING VALVE TIMING

Tool Required:
J-8520-Dial Indicator Adaptor
When it becomes necessary to make a check of valve
tim ing, the procedure following may be used:
1. Loosen the nut at the #1 intake valve rocker arm,
swing the rocker arm away from the pushrod, then
remove the pushrod.
MEASURING CAMSHAFT
LOBE LIFT
Tool Required:
J-8520 Dial Indicator Adaptor
To check for worn cam shaft lobes, use the following
procedure:
2. Install a dial indicator (part of J-8520) (figure 26).
Position the dial indicator so the plunger rests on
the pushrod end, as shown, Make sure the pushrod
is in the lifter socket.
4.8 LITER L6 6A7-15
A.
90.
91.
92.
93.
94.
Tinning M arks
C a m s h a ft
T h ru s t Plate
C a m s h a ft G ear
T h ru s t P late B o lts
C ra n k s h a ft G ear
uj-u /363
Figure 27Camshaft And Components

3. Rotate the crankshaft slowly in the direction of
rotation until the hydraulic lifter is on the heel of the
cam lobe. At this point, the pushrod will be in its
lowest position. Set dial indicator on zero, then
rotate the crankshaft slowly until the pushrod is in
the fully raised position.
4. C om pare the total lift recorded from the dial
indicator with specifications.
5. Continue to rotate the crankshaft until the indicator
reads zero. This will be a check on the accuracy of
the original indicator reading.
6. Remove the dial indicator and adaptor.
To c h e c k fo r w o rn c a m s h a ft lo b e s w ith o u t
disassem bling the engine, refer to Measuring Camshaft
Lobe L ift in this section.
++
1. Front end sheet m etal as required, dep en din g on

body builde r design.
Drain the cooling system .
2. Radiator, fan shroud, fan, and pulley.
3. A ir cleaner.
4. Fuel pum p.
5. R ocker arm cover, as o utline d previously.
6. D istributor. R efer to EN G IN E ELEC TR IC AL (SEC.
6D).
7. P ushrod covers, as outlined previously.
8. H ydraulic lifters, as outlined previously.
9. Torsional damper, as outline d previously.
10. T im in g gear cover, as outline d previously.
A lign the tim in g m arks (figure 27).
11. T h ru st plate bolts (39) (figure 28).
12. C a m s h a ft. S u p p o rt th e c a m s h a ft c a re fu lly to
avoid dam ag e to the c a m sh a ft b earings. On
som e vehicles, it m ay be necesary to d isco nn ect
th e front engine m ounting and raise the engine to
provide clearance.
C a m s h a ft lo b e s a nd jo u rn a ls fo r s c ra tc h e s ,
pitting, and wear.
T im in g g ear for dam aged teeth.
ffj
Measure (Figure 29)
T h ru st plate to cam shaft clea ra n ce. Use a

fe e le r g a g e ( fig u r e 2 9 ). T h e p r o p e r
c le a r a n c e is 0 .0 0 3 - 0 .0 0 8 - in c h . If th e
clearance is excessive, replace the th ru s t
plate. If th e clearance is insu fficien t, replace
the sp ace r ring. R efer to th e proper unit
repair m anual.
Camshaft Gear And Thrust Plate Replacement

Camshaft Bearing Replacement


C oat the ca m sh aft lobes and jo u rn a ls w ith a high
qua lity e ngine oil su pp le m en t (GM Engine Oil
S u pp lem en t or equivalent).
Figure 28Removing The Camshaft Thrust

Plate Bolts
6A7-16 4.8 LITER L6
Figure 29Measuring Camshaft To Thrust

Plate Clearance
A. G u id e Rod
1. C a m s h a ft (9 0 ) to th e e n g in e . H a n d le th e
ca m sh a ft ca re fu lly to prevent dam ag e to the
ca m sh aft bearings.
Line up the tim in g m arks on the crankshaft

gear and ca m sh a ft gear (figure 27).
Thrust plate bolts (94).
Tighten
T hru st plate bolts to 9.0 N m (80 in. lbs.).
Measure
B-05066
Figure 30Replacing the Connecting Rod

and Piston
CONNECTING ROD AND

PISTON REPLACEMENT
Tool R equired:
J-5239 Guide Set.
1. Cylinder head, as outlined previously.
C am shaft and crankshaft gear run-out. Use

ai d ia l in d ica to r. C a m s h a ft g e a r ru n -o u t
should not exceed 0.10 mm (0.004-inch),
cran ksha ft g ea r run-out should not exceed
0.08 m m (0.003-inch). If g ear run o ut is
excessive, the g ea r w ill have to be rem oved
and any burrs cleaned from the sh aft or the
gear w ill have to be replaced.
Tim in g gear backlash. Use a dial indicator.
T h e c o rr e c t b a c k la s h is 0.10-0.15 m m
(0.004-0.006-inch) w ith new parts, 0.20 mm
(0.008-inch) m axim um w ith used parts.
4. Timing gear cover, as outlined previously.
6. Hydraulic lifters, as outlined previously.
Im portant
R eplace all h yd ra u lic lifters, ch a n g e the
crankcase oil and filter, and add GM Engine
Oil S u ple m e nt (or equivalent) to the engine
oil if a new ca m sh aft w as installed.
7. Pushrod covers, as outlined previously.
6D).
10. Fuel pump.
11. Air cleaner.
12. Radiator, fan, pulley, and shroud.
grade of coolant.
13. Front end sheet metal, as required.
3. Oil pump, as outlined previously (if necessary).

4. Ridge or deposits from the upper end of the cylinder
bores.
reamer.
5. Connecting rod cap. Check the connecting rod and
cap for ide ntifica tion marks. M ark the parts if
Attach J-5239 to the connecting rod bolts
(figure 30).

unit repair manual.
Piston rings.
Cylinder bores.
4.8 LITER L6 6A7-17
____
ENGINE FRONT
" A OIL RING SPAC ER GAP

/
- C "
\ /
(TANG IN HOLE OR SLO T W ITH IN ARC )

B " O IL RING RAIL GAPS
C" 2ND C O M PR ESSIO N RING GAP
D" TOP CO M PRESSIO N RING GAP
IN L IN E -A L L CYL.
A-7809
Figure 31Piston Ring Gap Location

1.
2.
Tools R equired:
cylinder.
Connecting rod bearings.
size.
Install the bearing inserts in the connecting
rod and connecting rod cap.
Piston and connecting rod to the proper bore.
J-5239 onto the connecting rod studs (figure
30).
engine oil.
The piston must be installed so that the piston
crown d epressions fla t side faces to the
engines left side (figure 33).
Place the piston in its m atching bore. Using
connecting rod to the crankpin with J-5239
(figure 30). Hold the ring compressor against
the block until all rings have entered the
cylinder bore.
2 , Measure
C onnecting rod b earing clearance. R efer to

the proper unit repair m anual.
Tighten
C on ne cting rod cap nuts to 60 N-m (44 ft.
lbs.).
Measure
C on ne cting rod side clearance. Use a fe ele r
g a g e b e tw e e n th e c o n n e c tin g rod a nd
cran ksha ft (figure 34). The co rrect clea ra n ce
is 0.006-0.017-inch.
A. F ro n t o f E n g in e
B. F ly w h e e l S id e o f E n g in e
C. P is to n D e p re s s io n F la t S id e
Figure 33Pistons Installed
B-05256
6A7-18 4.8 LITER L6
Figure 34Measuring Connecting Rod Side

Clearance
MAIN BEARING
REPLACEMENT
Tool R equired:
Spark plugs.
Main bearing caps.
caps m ust be retu rne d to th e ir o rig in a l
5. Lower main bearing inserts from the main bearing

caps.
6. Rear crankshaft oil seal, if necessary, as outlined
previously.
7. Upper rear main bearing insert.
Use a smali brass drift and hammer. Tap on
the insert, on the side opposite the bearing
tan, until the insert rotates out of position
(figure 35).
Use a pair of pliers with the jaws taped to
prevent damage to the crankshaft. Clamp the
insert to the crankshaft flange (figure 35).
Rotate the crankshaft to remove the bearing
insert.
(figure 36).
Rotate the crankshaft to turn the bearing

Crankshaft.
M a in b e a rin g c a p re p la c e m e n t (s h im m in g
procedure).

Tool R equired:
J-8080-Main Bearing Remover/Installer
Figure 35Removing The Upper Rear Main Bearing Insert
4.8 LITER L6 6A7-19

the block.
Remove the tool.
caps.
Measure
Figure 36Removing The Upper Main Bearing

Insert
M ain b earing clearance. R efer to the proper

unit repair m anual. If the engine is in the
vehicle, the crankshaft m ust be su pp orte d
upw ard to rem ove any clearance from the
upp er bearing. The total clerance can then
be m easured betw een the lower bearing
and jou rn a l.
block. Make sure the special bolt which retains the
oil pump screen bracket is installed in the proper
position. (#5 main bearing cap, camshaft side hole.)
Tighten
1. Upper rear main bearing insert.
Apply engine oil to an insert of the proper size.
of the insert between the crankshaft journal
and the notched side of the block.
Use p lie rs w ith ta pe d jaw s to clam p the
bearing to the crankshaft as shown in figure
35. Rotate the crankshaft to roll the insert
into the block. Then seat the insert using a
small drift and hammer.
2. Lower rear main bearing insert.
Apply engine oil to an insert of the proper size.
Press the insert into the rear main bearing
cap.
M ain bearing cap bolts to 90 N m (65 ft.

lbs.).
6. Rear crankshaft oil seal to the block and main
bearing cap, as outlined previously.
7. Rear main bearing cap to the block.
Apply a brush-on type oil sealing com pound to
25). Do not a llow any s e a la n t on e ith e r
Tighten the bolts tem porarily to 14 N m (10 ft.
lbs.).
Measure
C ra nksh a ft end play, as follow s:
Tap th e end of th e c ra n k s h a ft firs t
re a rw a rd th e n fo rw a rd w ith a lead
bearing and crankshaft thrust surfaces.
to 90 N m (65 ft. lbs.).
W ith the c ra n ksh a ft forced forw ard,
bearing with a feeler gage (figure 37).
The proper clearance is 0.05-0.15 mm
(0.002-0.006-inch).
10. Spark plugs.
CRANKSHAFT GEAR
REPLACEMENT
A.
B.
100.
101.
F o rw ard
F e e le r G age
R ear M ain B e a rin g C ap
C ra n k s h a ft

B-07878
Figure 37Measuring Crankshaft End Play
Tool R equired:
J-24420-A Puller.
1.
2. Crankshaft gear. Use J-24220-A (figure 38).
6A7-20 4.8 LITER L6
VALVE REMOVAL
VALVE INSTALLATION
B-03497
Figure 39Replacing The Oil Filter

Bypass Valve
1. Oil pressure relief valve. Tap into place. Use a
9/ie -inch thin wall deep socket as a driver (figure
39).
2. Oil filter.
3. Engine oil, as necessary.
1. Remove the engine.
replacement procedure.
H" Install or Connect (Figures 27 and 38)

Tool R equired:
J-5590 Crankshaft Gear Installer.
1. Crankshaft gear. Use J-5590 (figure 38). Make sure
the tim ing mark faces out.
Im portant
A lign the tim in g m arks (figure 27).
2. Timing gear cover, as outlined previously.
1. Transm ission, clutch housing, and clutch.

2. R e a r m a in b e a r in g c a p . R e fe r to R e a r
C ra nksh a ft Oil Seal R e p la c e m e n t in th is section.
M ark the flyw heel and cra n ksh a ft so the dowel
pin holes can be aligned in th e ir o rigin al positions
at assem bly (figure 40).
Loosen the flyw heel bolts a few turns.
3. Flyw heel dowel pins.
Turn the crankshaft so that a dowel pin is at
the 6 oclock position.
Drive the dowel pin out, using a hammer and
drift.
Repeat the preceding steps to drive out the
remaining dowel pins. The crankshaft must be
turned each time so that the pin can be driven
out w ithout contacting the block.
4. Flywheel bolts.
5. Flywheel.
Clean
OIL FILTER BYPASS

VALVE REPLACEMENT
1. Oil filter.
2. Oil filte r relief valve. Pry it from the b lock w ith a
screw driver (figure 39).
M a tin g s u rfa c e s o f c ra n k s h a ft and fly w h e e l.

R em ove any burrs.
Inspect
Flyw heel
R e p la c e
m achine
Flyw heel
for burning, sco ring , w arping, and wear.

th e fly w h e e l if n e c e s s a ry . Do n o t
the flyw heel.
ring gear for w orn or broken teeth.
4.8 LITER L6 6A7-21

5. Transmission, clutch housing, and clutch.
ENGINE MOUNTINGS
m o u n tin g b re ak ag e o ccurs, the re m ain in g
stresses.

Figure 40Flywheel Dowel Pin Hole Locations

this will change m etal structure.
2. Uniformly heat the flywheel gear to temperature
which will expand the gear to permit installation.
Temperature must not exceed 2 0 4 C (400F).
flywheel.
1. Flyw heel to the crankshaft. A lign the m arks m ade

at disassem bly. M ake sure the dow el holes in the
cran ksha ft and flyw heel are aligned.
Flyw heel.

3. Dowel pins.
The in te rfe re n c e fit dow el pin s m ust be
replaced with an oversized dowel pin when
installing the flywheel.
Ream the dowel pin holes to the proper size
(0.4510-0.4517-inch).
Tap the dowel pins into place, flush with the
flywheel retaining bolt surface.
Rear main bearing cap. Refer to Rear Crankshaft
Oil Seal Replacem ent in this section.
1. R aise th e e n g in e to rem ove w e ig h t from th e

m ountings and to palce a slight tension on the
rubber cushion. Observe both m ountings w hile
raising the engine.
2. Replace the mounting if the following conditions
exist:
cracks.
R ubber cushion separated from the metal
m ounting and its attaching points, lower the engine
and tighten the bolts or nuts attaching the m ounting
Rear Mountings
1. Push up and pull down on the transm ission tailshaft.
Observe the transm ission mounting.
2. Repalce the m ounting if the following conditions
exist:
R ubber cushion separated from the metal
M ou ntin g bottom ed out (ta ils h a ft can be
b o lts or n u ts a tta c h in g th e m o u n tin g to th e

+- Remove or Disconnect (Figures 41 and 42)
S upport the eng in e w ith a su itab le liftin g fixture.
Do not load the e ngine m ounting.
1. Engine m ou ntin g thro ug h -b olt and nut.
Raise the eng in e only enough to p e rm it rem oval
of the eng in e m ounting.
2. M ounting assem bly bolts, nuts, and w ashers.
3. M ounting assem bly.

section for steps 2 and 3.
2. Mounting assem bly bolts, nuts, and washers.
6A7-22 4.8 LITER L6
150

A. 48 N m (36 ft. lbs.)
B. Torque N u t To 68 N m (50 ft. lbs.) Or, Torque
B o lt To 100 N-m (75 ft. lbs.)
C. Forw ard
B-07883
Figure 41Front Engine Mounting Brackets

Tighten
Fasteners to sp ecifications. R efer to figures
41 and 42.
3. Engine m ount through-bolt and nut. Lower the
engine until the bolt can be inserted. Install the nut.
Tighten
T hro ug h-bo lt or nut to sp ecifications. Refer
to fig ure 41.

(P-MODELS WITH TRANSMISSION TAIL MOUNTING)
S u pp o rt the rear of the engine to relieve the
w eig ht on the rear m ountings.
1. M ounting to crossm em be r nut(s) and washer(s).
2. M ounting to tran sm issio n bolts and washers.
Raise the rear of the e ngine only enough to
p erm it rem oval of the m ounting.
3. M ounting.

1. M ounting.
2. M ounting to tran sm issio n bolts and washers.
A. 40 N-m
B. F orw ard
150. M o u n tin g A s s e m b ly
152. Fram e B ra cket
B-07894
section.
3. Mounting to crossm em ber nut and washer.
Figure 42Front Engine Mountings (P Models)
4.8 LITER L6 6A7-23
MODELS WITH PROPSHAFT PARKING BRAKE
A.
B.
C.
D.
F orw ard
68 N m (50 ft. lbs.)
48 N m (36 ft. lbs.)
60 N-m (44 ft. lbs.)
MODELS WITHOUT PROPSHAFT PARKING BRAKE

B-07901
Figure 43Rear Engine Mounting (P Models With Transmission Tail Type Mounting)
6A7-24 4.8 LITER L6

10.
11.
12.
13.
14.
15.
16.
17.
18.
Evaporate em ission and o the r vacuum hoses.

Engine w iring.
Starter.
Exhaust pipe at the e xhaust m anifold. W ire the
pipe out of the way.
Flywheel cover.
F lyw heel to to rq ue c o n v e rte r bolts (a u to m a tic
transm ission).
A ttach a su itab le lifting device to the engine.
Rem ove the w eig ht from the engine m ountings.
Front engine m ounting through-bolts.
S u p p o rt th e tr a n s m is s io n w ith a c h a in o r
transm ission jac.
Bell housing to engine bolts.
Engine. Move the eng in e forw ard to dise ng ag e
the transm ission and rem ove.

Figure 44Rear Engine Mounting (P Models
With Flywheel Housing Type Mounting)
Engine. Move the e ngine rearw ard to engage the

transm ission.
2 . B e ll h o u s in g to e n g in e b o lts . R e m o v e th e
tran sm issio n ja ck or su p p o rt chain.
Front eng in e m ounting th ro ug h -b olts and nuts.
Tighten
Fasteners to specifications. R efer to figure

43.
REAR MOUNTING REPLACEMENT (P-MODELS

WITH FLYWHEEL HOUSING MOUNTING
4.

1. Bolt, cushion and spacer.
Raise the rear of the engine only enough to
p erm it rem oval of the m ounting.
2. M ounting.

1. M ounting. A lign the hole in the m ounting w ith the
hole in the crossm em ber.
NOTICE: See N o tic e on page 6A7-1 of this
section.
2. Spacer, cushion and bolt.
Tighten
ENGINE REPLACEMENT
Additional steps may be necessary on P models
depending on body builder design.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Hood and sheet m etal, as required.
A ir cleaner.
Radiator.
H eater hoses from the engine.
A ccelerator cable.
Transm ission detent cable (if used).
Fan and w ater pum p pulley.
Fuel lines from the fuel pump.
5.
6.
7.
8.
9.
10.
11.
12 .
13.
14.
15.
16.
17.
18.
19.
Fasteners to specificatio ns. Refer to figure

41.
Remove the lifting device.
Torque c o n v e rte r to fly w h e e l b olts (a u to m a tic
transmission).
Flywheel cover.
Exhaust pipe and new packing to the exhaust
manifold.
Starter.
Engine wiring.
Vacuum hoses.
Fuel lines.
Fan and water pump pulley.
Transmission detent cable (if used).
Accelerator cable.
Heater hoses.
Radiator.
Air cleaner.
Hood and sheet metal.
Proper quantity and grade of coolant.
4.8 LITER L6 6A7-25
SPECIFICATIONS
GENERAL DATA:
In L in e
Type
4 .8 L ( 2 9 2 C u . In .)
D is p la c e m e n t
N o . O f C y lin d e r s
3 .8 7 6
B o re
S tro k e
4 .1 2
C o m p r e s s io n R a tio
8 .0 :1
1 - 5 - 3 - 6 - 2 - 4
F ir in g O r d e r
16 psi @
O il P r e s s u r e
7 0 0 R P M ; 3 0 -4 5 p si @
1500 R PM
CYLINDER BORE:
3 .8 7 5 0 -3 .8 7 8 0
D ia m e te r
O ut O f
P r o d u c tio n
Round
S e r v ic e
P r o d u c tio n
Taper
0 .0 0 0 5 (M a x im u m )
0 .0 0 2 (M a x im u m )
T h r u s t S id e
0 .0 0 0 5 (M a x im u m )
R e lie f S id e
0 .0 0 0 5 (M a x im u m )
0 .0 0 1 ( M a x im u m )
S e r v ic e
PISTON:
0 .0 0 2 6 -0 .0 0 3 6
P r o d u c tio n
0 .0 0 4 5 (M a x im u m )
S e r v ic e L im it
PISTON RING:
C
0
M
p
Top
G ro o v e
P r o d u c tio n
Ploaran np
R
t
S
P r o d u c tio n
G ap
1
0
N
G ro o v e
C le a r a n c e
0 .0 0 2 0 -0 .0 0 4 0
2nd
P r o d u c tio n
P r o d u c tio n
H i L im it P r o d u c tio n
Top
0 .0 1 0 -0 .0 2 0
2nd
0 .0 1 0 -0 .0 2 0
H i L im it P r o d u c t io n
0 .0 0 1
0 .0 1 0
0 .0 0 1
0 .0 0 5 -0 .0 0 5 5
H i L im it P r o d u c tio n
0 .0 1 5 -0 .0 5 5
H i P r o d u c tio n
+ 0 .0 1 0
PISTON PIN:
0 .9 2 7 0 -0 .0 9 2 7 3
D ia m e te r
C le a r a n c e
P r o d u c tio n
In P is t o n
F it In R o d
0 .0 0 0 1 5 -0 .0 0 0 2 5
0 .0 0 1 ( M a x im u m )
0 .0 0 0 8 -0 .0 0 1 6 In te r fe r e n c e
B-07896
6A7-26 4.8 LITER L6
SPECIFICATIONS
CRANKSHAFT:
Diameter
Main
Journal
Production
Service Limit
Production
Service Limit
Taper
Out of
Round
Main
Bearing
Clearance
Production
Service Limit
Crankshaft End Play

Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
Taper
Crankpin
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
All
2.2979-2.2994
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
#1-#6: 0.0010-0.0024
#7: 0.0016-0.0035
#1-#6: 0.0010-0.0025
#7: 0.0015-0.0035
0.002-0.006
2.099-2.100
0.0005 (Maximum)
0.001 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.0010-0.0026
0.0030 (Maximum)
0.006-0.017
CAMSHAFT:
Lobe
Lift 0.002
Journal Diameter
Camshaft Runout
Camshaft End Play
Intake
Exhaust
0.2315
0.2315
1.8677-1.8697
0.020 (Maximum)
0.003-0.008
VALVE SYSTEM:
Lifter
Rocker Arm Ratio
Hydraulic
1.75:1
Intake
Exhaust
Valve Lash
Seat Width
Stem
Clearance
Valve
Spring
(Outer)
Valve
Spring
Damper
Production
Service
Free Length
Pressure
lbs. @ in.
O
CO

Seat Runout (Intake & Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Closed
Open
Installed Height
V32"
Free Length
Approx. # of Coils
46
0.002 (Maximum)
0.035-0.060
0.062-0.093
0.0010-0.0027
0.0015-0.0032
2.08
78-86 lbs. @ 1.66"
170-180 lbs. @ 1.26"
121/32
1.94
4
B-07898
4.8 LITER L6 6A7-27
Item
Nm
Ft. Lbs.
In. Lbs.
Flywheel Bolts
150
110
Flywheel Housing Bolts
40
30
Main Bearing Cap Bolts
90
65
Cam shaft Thrust Plate Screws
9.0
80
Timing Gear Cover Bolts To Block
9.0
80
Torsional Damper Bolt
70
50
Connecting Rod Cap Nuts
60
44
Oil Pump Bolts
13.0
115
Oil Pump Pickup Tube Bracket Nut (To Main Bearing Cap Bolt)
34
25
Oil Pump Cover Bolts
7.9
70
Oil Pan Bolts (To Front Cover)

(To Block [1/4-20])
(To Block [5/i 6-18])
5.1
9.0
18.6
45
80
165
C ylinder Head Bolts (Left-Hand Front Bolt)

(All Others)
115
130
85
95
Rocker Arm Cover Bolts (Cork Gasket)
4.3
38
Pushrod Cover Bolts
9.0
80
Water Pump Bolts
20
15
Thermostat Housing To Block Bolts
38
28
Water Outlet to Thermostat Housing Bolts
28
20
Intake Manifold To Exhaust Manifold Bolts And Nuts
60
44
Manifold To Cylinder Head Bolts And Nuts
52
38
Spark Plug
20
15
6A7-28 4.8 LITER L6
SPECIAL TOOLS
1.
tV .
o
J-9290-01
J-23523-E
eir
<>
2.
J-5892-B
3.
J-23590
4.
J-35468
5.
J-8080
10.
J-3049
11.
J-5802-01
12.
13.
J-5715
J-6036
14.
15.
6.
J-6880
J-24420-A
J-8037
16.
J-5590
J-5239
8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
17.
J-23738-A
Torsional Dam per Remover and In staller

Valve S pring C o m pressor
A ir A dapter
C rankshaft Seal In s ta lle r and C entering Tool
Main Bearing R eplacer
Piston Ring C o m pressor
G uide Set
Vacuum Pump
H ydraulic L ifte r Rem over (Slide Ham m er Type)
J-8520
S=
10.
11.
12.
13.
14.
15.
16.
17.
H ydraulic L ifte r Remover (Plier Type)

Stud Remover
Stud In staller
C rankshaft Gear Puller
C rankshaft Gear In sta lle r
Dial In d ica to r Adapter
B-08357
6B-1
SECTION 6B1
ENGINE COOLING
CONTENTS
SUBJECT
PAGE
Description.................................................................................................................................................................. 6B1- 1
Diagnosis.................................................................................................................................................................... 6B1- 2
System Checks........................................................................................................................................................ 6B1- 2
Fan Clutch Diagnosis..............................................................................................................................................6B1- 2
Thermostat Diagnosis............................................................................................................................................6B1- 3
Coolant Level Indicator Diagnosis....................................................................................................................... 6B1- 3
Cooling System D iagnosis....................................................................................................................................6B1- 5
Uncommon Cooling System P ro b le m s............................................................................................................... 6B1- 5
On Vehicle S>ervice.................................................................................................................................................... 6B1- 6
Flushing The Cooling System................................................................................................................................6B1- 6
Coolant Recovery Tank Replacem ent................................................................................................................. 6B1- 6
Deaeration Tank Replacement..............................................................................................................................6B1- 6
Thermostat Replacem ent......................................................................................................................................6B1- 7
Thermostat Housing Crossover R em oval........................................................................................................... 6B1- 8
Drive Belt Replacement..........................................................................................................................................6B1-10
Fan And Fan Clutch Replacement....................................................................................................................... 6B1-13
Auxiliary Cooling Fan Replacement..................................................................................................................... 6B1-14
Water Pump Replacement......................................................................................................................................6B1-15
S pe cifica tio n s............................................................................................................................................................ 6B1-30
Special T o o ls .............................................................................................................................................................. 6B1-32
DESCRIPTION
All R/V, G and P series vehicles have pressure type
engine cooling systems with therm ostatic control of the
coolant circulation. The cooling system is sealed by a
pressure type radiator cap that causes the system to oper
ate at higher than atmospheric pressure. This higher
pressure operation raises the boiling point of the coolant,
thereby increasing the cooling efficiency of the radiator.
The 105 kPa (15 psi) pressure cap raises the boiling point
of the coolant to approximately 125C (258F) at seal
level.
The pressure-vacuum valve radiator cap allows the
coolant to expand through the pressure valve in the cen
ter of the cap without building unnecessary pressure. This

expanding coolant flows into the coolant reservoir. The
vent valve closes due to expansion and coolant flow (the
nominal 105 kPa (15 psi) pressure will not be reached until
the system is working at maximum capacity). Any air or
vapor in the cooling system will be forced into and out of
the coolant reservoir through the vent tube at the top of
the reservoir. As the system cools, the extra coolant in the
reservoir will be drawn back to the radiator through the
vent valve. In this manner, the radiator will keep itself full
at all times.
6B1-2 ENGINE COOLING
DIAGNOSIS
SYSTEM CHECKS
EXHAUST LEAKS
To check for exhaust leaks into the cooling system,
drain the system until the coolant level stands just above
the top of the cylinder head(s), then disconnect the
radiator upper hose and remove the therm ostat and fan
belt(s). Start the engine and accelerate several times. At
the same time note any appreciable coolant rise or the
appearance of bubbles which may indicate that exhaust
gases are leaking into the cooling system.
NOTICE: A worn head gasket may allow exhaust
gases to leak into the cooling system. This can
d am age the c o o lin g system as the gases
combine with the water to form acids which are
harmful to the radiator and engine.
WATER PUMP
Check water pump operation by running the engine
while squeezing the radiator upper hose. When the
engine warms a pressure surge should be felt. Check for
a plugged venthole in the pump.
Diagnosis/Inspection
1. Isolate the area by probing the engine w ith a
sounding bar (large screwdriver).
2. With the radiator cap removed, observe the water
being circulated in the radiator. Feel the front area of
the radiator for cold spots which indicate blockage.
Blocked radiators generally occur on units that have
accrued miles and not on new vehicles.
CAUTION: The radiator cap should be removed

from a cool engine only. If the radiator cap is
removed from a hot cooling system, serious
personal injury may result.
3. Inspect the therm ostat to see if it opens.
4. Inspect the therm ostat housing to make sure it is
free of obstructions.
5. Remove the water pump from the vehicle and the
back cover on the pump. Inspect internal passages
using a flash light.
6. Inspect the cross over at the front of the inlet
manifold. This entire passage can be seen with the
therm ostat removed.
7. Remove the heads, and check the block.
RADIATOR
Test for restrictions in the radiator by warming the
engine and then turning the engine off and feeling the
radiator. The radiator should be hot along the left side and
warm along the right side, with an even temperature rise
from right to left. Cold spots in the radiator indicate
clogged sections.
THERMOSTAT
Check the therm ostat by hanging the therm ostat on a
hook in a 33% glycol solution, 25C (4F) above the
temperature stamped on the therm ostat valve. Submerge
the valve and agitate the solution. The valve should open.
Remove the therm ostat and place it in a 33% glycol
solution, -12C (10F) below the temperature indicated on
the valve. With the valve submerged and coolant agitated,
the valve should close.
8. With the water pump and heads removed, inspect

the coolant passages by using a pen light flash
light. Replace the block if a restriction can be seen.
9. If none of the above inspections reveal the problem
area, inspect the heads. Heads with blocked coolant
passages generally have more than one area that is
blocked. Inspect the heads for signs of overheat
discoloration (a dark blue or black area). If none are
found, look in the coolant passages for blockage
and probe all accessible passages.
Use a substantial probe as a tag wire to go through
or around a partially blocked area. If nothing is
found by visual inspection and probing, inspect the
passages for a rough, ragged appearance. The
roughest internal passages are probably the ones
that are blocked.
Replace a blocked or suspect head and inspect the
replacement head before installation.
OVERHEAT AND/OR NOISE

Restrictions in the cooling system can cause the engine
to overheat and/or create cooling system noise.
Components prone to this condition are the cylinder
head, water pump, block, therm ostat housing and inlet
manifold. Symptoms include:
FAN CLUTCH DIAGNOSIS

NOISE
Fan noise is sometimes evident under the following
normal conditions.
Engine may make snapping/cracking noises.
When the clutch is engaged for maximum cooling.
Heater core may gurgle or surge.
During the first few minutes after start-up until the

clutch can re-distribute the silicone fluid back to its
norm a l d is e n g a g e d o p e ra tin g c o n d itio n (a fte r
overnight settling).
Radiator hoses may collapse and expand.

Heater hoses may vibrate and thump.
Overheat light may or may not come on.
Symptoms are the result of coolant boiling at some
localized area and may be noticed after extending idling
and/or while driving. Determine which side of the engine
is involved and whether it is more at the front or rear of
the engine.
Fan noise or an excessive roar will generally occur

continuously under high engine speed conditions (2500
rpm and up) if the clutch assem bly is locked up due to an
internal failure. If the fan cannot be rotated by hand or
there is a rough grating feel as the fan is turned, replace
the clutch.
ENGINE COOLING 6B1-3
NOTE: THE TEMPERATURE STICK IS A PENCIL LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING
CERTAIN CHEMICALS WHICH MELT AT A GIVEN TEMPERATURE. TEMPERATURE STICKS CAN BE USED TO
DETERMINE A THERMOSTATS OPERATING TEMPERATURE BY RUBBING 86.6C (188F) AND 96.6C
(206F) STICKS ON THE THERMOSTAT HOUSING. THE MARKS MADE BY THE STICKS SHOULD MELT WHEN
COOLANT TEMPERATURES OF 86.6C (188F) AND 96.6C (206F) ARE REACHED, RESPECTIVELY. THESE
TEMPERATURES ARE THE NORMAL OPERATING RANGE OF THE THERMOSTAT, THEREFORE, IF THE
COOLANT FLOWS AS INDICATED ON THE DIAGNOSIS CHART, THE THERMOSTAT MAY BE WORN
B -0 7 5 4 0
Figure 1Thermostat Diagnosis Chart

LOOSENESS
Check a loose fan assembly for any wear and replace if
necessary. Under various temperature conditions a visible
lateral movement that can be observed at the tip of the
fan blade. This is a normal condition due to the type of
bearing used. Approxim ately 6.5 mm (1/4-inch) maximum
lateral movement measured at the fan tip is allowable.
This is not cause for replacement.
THERMOSTAT DIAGNOSIS
Refer to the therm ostat diagnostic chart for therm ostat
diagnosis procedures (figure 1).
COOLANT LEVEL INDICATOR

DIAGNOSIS
INDICATOR LAMP WILL NOT ILLUMINATE
SILICONE FLUID LEAKS

The fan clutch operation is generally not affected by
small fluid leaks which may occur in the area around the
bearing assembly. If leakage appears excessive, replace
the fan clutch (see below).
ENGINE OVERHEATING
If the fan and clutch assembly free-wheel with no drag
(revolves more than five tim es when spun by hand),
replace the clutch.
1. Turn the ignition switch to the CRANK position.

If the lamp illuminates, the lamp is OK and the
connector is properly installed on the module.
Go to Step 2.
If the lamp does not illuminate, check the bulb,
socket and wiring between the socket and the
module connector and the connector on the
module. Replace or repair as required.
2. Turn the ignition switch to the ON position and
disconnect the electrical lead a t the coolant level
sensor on the radiator.
COOLING SYSTEM DIAGNOSIS CHART A
F-02619
Figure 2Cooling System Diagnosis Chart

If the lamp fails to illuminate, check the wiring
between the coolant level sensor connector
and the module for a short circuit to ground. If
the circuit is OK, replace the module.
COOLING SYSTEM DIAGNOSIS - CHART B
INDICATOR LAMP REMAINS ILLUMINATED

1. Turn the ignition switch to ON.
C he ck th e c o o la n t level. Add c o o la n t if
necessary.
If the lamp remains illuminated, go to Step 2.
2. Disconnect the electrical lead at the coolant level
sensor on the radiator (use a jum per wire and G
type electrical connector).
If the lamp does not illuminate, replace the
sensor.
IM he lamp remains illuminated, connect the
electrical lead and go to Step 3.
3. Check for an open circuit between the sensor and
the module.
If an open circuit is found, repair it.
If no open circuit is found, replace the module.
COOLING SYSTEM DIAGNOSIS

Refer to the cooling system diagnosis chart for detailed
cooling system diagnostic procedures (figures 2 and 3).
UNCOMMON COOLING SYSTEM

PROBLEMS
PROBLEMS NOT REQUIRING DISASSEMBLY OF
THE COOLING SYSTEM
1. Locate and remove large obstructions blocking the
radiator or the condenser.
Auxiliary oil cooler.
License plates.
Spare tires.
Ice, mud, or snow obstructing the grille.
2. Engine oil is overfilled.
3. Incorrect radiator for the application.
Check the part number.
4. Loose, damaged, or missing air seals.
5. Missing or damaged lower air baffle.
6. Incorrect ignition timing.
PROBLEMS REQUIRING DISASSEMBLY OF THE

COOLING SYSTEM
F-02620
Figure 3Cooling System Diagnosis Chart
1. Incorrect or damaged fan.

2. Worn or dam aged emission system components.
Could cause overheating at idle.
Damaged PCV valve, TVS or TCS.
3. P re ssu re c h e c k th e c o o lin g system w ith the
pressure cap installed.
Shows if the pressure cap leaks because of
radiator filler neck damage.
4. Worn or damaged water pump.
Impeller vanes eroded or broken.
Worn or damaged bearing and/or seal-check
for shaft or bearing play.
5. Plugged radiator tubes.
Perform a flow check.
6. Internal system leaks.
Head gasket.

Cracked block.
Timing chain cover.
Intake manifold gasket.
7. Plugged coolant passages in the cylinder heads.

Visual check.
ON VEHICLE SERVICE
1. R ecovery Tank
2. B o lt/S c re w
3. Cap
4. R eturn H ose
5. R a d ia to r A s s e m b ly
6. N ut
B-07542
Figure 4R/V - Coolant Recovery System
FLUSHING THE COOLING

SYSTEM
Various methods and equipm ent can be used to flush
the cooling system. If special equipm ent is used, follow
the equipm ent m anufacturers instructions.
DEAERATION TANK
REPLACEMENT
1. Coolant from the deaeration tank (10).
2. Overflow hose from the filler neck.
3. Return hose (12) from the deaeration tank (10).
Remove the therm ostat before flushing the

cooling system.
4. Deaeration tank (10) from the vehicle.

For R/V and P vehicles; bolts/screws (7), and
the reta inin g strap s (8) from the su p p o rt
brackets (9) (figures 6 and 8).
COOLANT RECOVERY TANK

REPLACEMENT
For the G series vehicle; bolts/screws (7) and

nut (6) (figure 7).
The deaeration tank (10) is free of the vehicle.

1. Coolant from the recovery tank (1).
2. Coolant overflow hose from the recovery tank (1).
-+ Install or Connect (Figures 7, 8 and 9)

Deareation tank (10) to the vehicle.
For R/V and P vehicles; deaeration tank (10)
onto the support brackets (9). A ttach the
retaining straps with bolts/screws around the
tank and the lip on the support brackets (9).
3. Coolant recovery tank (1) from the vehicle.

Bolt/screw (2).
" Install or Connect (Figures 4, 5 and 6)
For the G vehicle; deaeration tank (10) into

position and attach with bolts/screws (7) and
the nut (6).
1. Coolant recovery tank (1), to the vehicle.

Bolt/screw (2).
Tighten
&
Tighten
Bolt/screws (7) and nut (6) to Specifications.
Bolt/screw (2) to 2.0 N m (1.5 ft. lbs.).
2. Return hose (12) to the deaeration tank (10).
2. Coolant overflow hose to the recovery tank (1).
3. Overflow hose to the filler neck.
3. Coolant to the recovery tank (1).
4. Coolant into the deaeration tank (10).
A.
B.
1.
2.
3.
4.
5.
G S eries A rra n g e m e n t W ith o u t A ir C o n d itio n in g

G S eries A rra n g e m e n t W ith A ir C o n d itio n in g (N o t 6.2L D iesel)
R ecovery Tank
B o lt/S cre w
C ap
R eturn H ose
R a d ia to r A s s e m b ly
B-07543
Figure 5G - Coolant Recovery System
THERMOSTAT REPLACEMENT
VEHICLES EXCEPT THOSE WITH 6.2L ENGINE
1. Drain the cooling system until the radiator coolant
level is below the thermostat.
2. Thermostat (23) from the vehicle.
Bolts (20) and the water outlet (21).
Thermostat from its housing.
Tighten
For bolts (20), refer to Specifications.
4. Fill the cooling system.
5. Start the engine and run with the radiator cap
re m o ve d u n til th e ra d ia to r u p p e r hose
becomes hot (thermostat is open).
6. With the engine idling, add coolant to the
radiator until the coolant level reaches the
bottom of the filler neck.
7. Radiator cap to the radiator, making sure the
arrows line up with the overflow tube.
Gasket.
VEHICLES WITH THE 6.2L ENGINE

Make sure the thermostat housing and water outlet
sealing surfaces are clean.
1. Thermostat (23) in its housing.
2. New gasket (22) into position.
3. Water outlet (21).
Bolts (20).

1. Upper fan shroud from the G vehicle.
Refer to RADIATOR (SEC. 6B2).
2. Drain the cooling system until the radiator coolant
level is below the thermostat.
3. Engine oil dipstick tube brace and the oil fill brace
on the G vehicle.

Gasket (22) into position.
Water outlet (21).
Studs (26) and the upper radiator inlet hose.
Studs (26) to 47 N m (35 ft. lbs.).

4. Engine oil dipstick tube brace and the oil fill brace
on the G vehicle.
Refer to 6.2L DIESEL (SEC. 6A6).
5. Upper fan shroud on the G vehicle.
6. Fill the cooling system.
7. Start the engine and run, with the radiator cap
re m o ve d , u n til th e ra d ia to r u p p e r hose
becomes hot (thermostat is open).
8. With the engine idling, add coolant to the
radiator until the coolant level reaches the
bottom of the filler neck.
9. Radiator cap to the radiator, making sure the
THERMOSTAT HOUSING
CROSSOVER REPLACEMENT
R/V VEHICLE WITH 6.2L ENGINE
1. Coolant from the radiator.
2. Crankcase depression regulator valve.

Refer to 6.2L DIESEL (SEC. 6A6).
4. Thermostat (23) from the vehicle.
Studs (26) and the water outlet (21).
Upper radiator inlet hose.
Thermostat from its housing.
Gasket (22).
- Install or Connect (Figures 15 and 16)
Make sure the therm ostat housing and water outlet
sealing surfaces are clean.
1. Thermostat (23) into its housing.

4. By pass hose, upper radiator hose, and heater hose
5. Crossover (32) from the vehicle.
Bolts (27) from the vehicle.
Therm ostat (23) and water outlet (21) are
attached to the crossover along with the
thermal bypass nipple.
Make sure the crossover sealing surfaces are clean.
New gasket (28) into position.
Crossover (32) to the vehicle.
5. R a d ia to r A s s e m b ly
6. N ut
7. B o lt/S cre w
8 . R e ta in in g S tra p
9. S u p p o rt B ra cke t
10. D ea e ra tio n Tank
Figure 7R/V - Deaeration Tank Installation
Q
3.
4.
5.
6.
7.
5.
7.
8.
9.
10.
8. With the engine idling, add coolant to the radiator

until the coolant level reaches the bottom of the filler
neck.
Bolts (27).
Tighten

Heater hose, upper radiator hose, and bypass hose.
Crankcase depression regulator valve.
Start the engine and run, with the radiator cap
removed, until the radiator upper hose becomes hot
(thermostat is open).
R a d ia to r A s s e m b ly
B o lt/S c re w
R e ta in in g S trap
S u p p o rt B ra cket
D ea re a tion Tank
11. C la m p
12. R eturn H ose
14. R a d ia to r S u p p o rt
Brace
B-07547
Figure 9P - Deaeration Tank Installation
9. Radiator cap to the radiator, making sure the arrows

line up with the overflow tube.
Figure 104.3L Engine Thermostat Replacement

(R/V and P)
20. B o lt
21. W a te r O u tle t
(G, P S eries)
21 A. W a te r O u tle t
20.
21.
22.
23.
B o lt
W a te r O u tle t
G a ske t
T h e rm o s ta t
25.
26.
27.
28.
B o lt
S tud
T h e rm o s ta t H o u s in g
G a sket
B-08081

(R/V and P)
G AND P VEHICLES WITH 6.2L ENGINES
1.
2.
3.
4.
5.
6.
7.
8.

Engine cover from the G vehicle.
Air cleaner.
Air cleaner resonator and its bracket.
Upper fan shroud.
Bypass hose, upper radiator hose, and heater hose.
Crossover (32) from the vehicle.
Bolts (27), studs (26) and the gasket (28).
Therm ostat (23) and the water outlet (21) are
attached.

Make sure the crossover sealing surfaces are clean.
New gaskets (28) into position.
Crossover (32) to the vehicle.
Bolts (27) and studs (26).
&
3.
4.
5.
6.
7.
8.
Tighten

Studs (26) to 47 N m (35 ft. lbs.).
Heater hose, upper radiator hose, and the bypass
hose.
Upper fan shroud.
Air cleaner resonator and its bracket.
Air cleaner.
Engine cover on the G vehicle.
22.
23.
24.
26.
(C-K S eries)
G a ske t
T h e rm o s ta t
In le t M a n ifo ld
S tud
B-08082
Figure 125.0L and 5.7L Engine Thermostat

Replacement (R/V, G and P)
removed, until the radiator upper hose becomes hot
(thermostat is open).
11. W ith the engine idling, add coolant to the radiator
neck.
12. Radiator cap to the radiator, m aking sure the arrows
line up with the overflow tube.
DRIVE BELT REPLACEMENT

PULLEY INSPECTION
Examine the pulleys for chips, nicks, tool marks, cracks,
bent sidewalls, corrosion or other damage.
1. Place a straightedge or position a cord across the
two pulleys so they touch at all points (figure 17).
2. Turn each pulley one half revolution and recheck
with a straightedge or cord. Full contact at all points
must be made. If contact is not made at all points,
the pulley may be warped or its shaft could be bent.
Replace any damaged parts.
DRIVE BELT INSPECTION

Replace frayed or cracked belts and tension to the
proper specification. Do not use drive belt dressings to
extend the belt life.

(R/V and P)
CAUTION: Avoid over or under-tightening drive
belts. Loose belts result in slippage which can
cause belt and pulley glazing and inefficient
component operation. Once a belt has become
glazed, replace the belt. Loose belts can
also place high im p a ct loads on d rive n
component bearings due to the whipping action
of a loose belt. Over tightening belts can lead
to bearing damage and early belt failure.
DRIVE BELT REPLACEMENT - V-BELT
1. Remove the old belt.
Loosen the com ponent driven by the belt
(figures 18 through 22).
NOTICE: Place the belts into the pulley grooves
by hand. Do not force a belt into a pulley groove
by prying with a screwdriver, crowbar, or other
wedge type tool. Prying a belt into position can
d am ag e b o th th e b e lt a n d th e b e lt d rive
components.
2. Install the new belt.
Tension the new belt to Specifications
Use J-23600-B to measure V-belt tension.
Place the gage at the center of the greatest
span.
Tighten
Component to mounting bracket fasteners to
the Specifications at the end of this section.
(R/V)
3. Run the engine at idle speed for a minimum of 15
minutes.
This allows the belt to seat itself in the pulleys,
causing the belt fibers to relax, or stretch.
4. Allow the drive belt to cool until it is cool or at most,
warm to the touch. Not hot.
NOTICE: A used belt is one that has been
rotated at least one com plete revolution on the
engine pulleys. This begins the seating of
the belt and it must never be tensioned to new
belt specifications.
5. Check the belt tension.
span.
The belt tension should be at the maximum
used belt specifications from the chart in
Specifications.
DRIVE BELT ADJUSTMENT - V-BELT

Never tension a used belt to more than its specified
tension limit.
1. Check the belt tension.
Belt should be cool or at least warm to the
touch. Not hot.
span.
If the belt is below the minimum used b elt
tension specification, adjust the belt.

21. W a te r O u tle t
27. B o lt
28. G a ske t

(G and P)
29. N ip p le
30. C la m p
31. H ose
32. C ro sso ve r
H ose
B-08086
Figure 166.2L Engine - Crossover Replacement -
2. Loosen the com ponent in its m ounting bracket

(figures 18 through 2 2 ).
3. T ension th e b e lt to th e m axim u m used b e lt
specification from the chart in Specifications.
T ig h te n
Component to mounting bracket fasteners to
the specifications at the end of this section.
4. Run the engine at idle for a minimum of 15 minutes.
This allows the belt to reseat itself in the
pulleys.
5. Allow the drive belt to cool.
Should be at most warm to the touch. Not hot.
6 . Check the belt tension.
span.
R e -a d ju s t if n ot w ith in th e
s p e c ific a tio n s
fro m
th e
Specifications.
u se d b e lt
c h a rt
in
Figure 17Checking the Pulley Alignment
VIEW A
A.
B.
C.
40.
41.
4.8L L 6 E n gin e
4.3L V 6 , 5.0/5.7L V 8 E n g in e s
7.4L V 8 E n gin e
A d ju s tm e n t B o lt
P ivot B o lt
Figure 18Generator Adjustment (R/V, G and P)

DRIVE BELT ROUTING
R efer to th e d rive b e lt ro u tin g d ia g ra m s if b elt
replacement becomes necessary. Refer to figures 23 to
32.
FAN AND FAN CLUTCH

REPLACEMENT
DRIVE BELT REPLACEMENT - SERPENTINE BELT

1. Remove the old belt (figure 33).
With a socket and breaker bar, release the
te n s io n by tu rn in g th e te n s io n e r p u lle y
assem bly. The te nsio ne r p ulley is sprung
activitied and it can be turned to the left or
right to apply or release the pulley tension.
2. Install a new belt.
Thread the belt around the pulleys.
W ith a breaker bar apply the tension by
turning the tensioner pulley assembly.
DRIVE BELT ROUTING - SERPENTINE BELT

Refer to drive belt routing diagrams if belt replacement
becomes necessary (figure 33).
1. Radiator fan shroud.

2. Fan (73) and fan clutch (74) from the water pump
pulley (70).
Nuts (75).
3. Fan (73) from the fan clutch (74).
Bolts (72).
Inspect the mating surfaces (the water pump hub
and the fan clutch hub) for smoothness and rework
as n ecessary to e lim in a te any burrs o r other
imperfections.
A
B.
C.
D.
40.
41.
4 g L |_g E n gin e
4.3L V 6 , 5.0/5.7L V 8 E ngin es (N o t P o r G S eries)

4.3L V 6 5.0/5.7L V 8 Engine is (P and G Series)
7.4L V 8 E n gin e
A d ju s tm e n t B o lt
Pivot B o lt
B-08089
Figure 19Power Steering Pump Adjustment (R/V, G and P)

CAUTION: Do not repair and reuse a fan with a
bent or damaged blade. Replace the fan as an
assembly. A damaged blade can change the
balance of a fan. A fan out of balance could fly
apart during use and create a dangerous
condition to the owner and vehicle.
1. Fan (73) to the fan clutch (74).
Q
Tighten
AUXILIARY COOLING FAN

REPLACEMENT
The Auxiliary Cooling Fan is available when a 7.4L
engine (RPO LE 8 ) and Air C onditioning (C60, C69) are
ordered. Its to provide additional cooling at low speed
vehicle operations, extended idle, stop and go conditions,
and when running the air conditioning system.
+ Remove or Disconnect (Figure 35)

2. Fan and clutch assembly to the water pump pulley
(70).
Nuts (75). Align the yellow reference marks on
the water pump hub and the fan clutch hub.
Tighten
Nuts (75) to 25 N m (18 ft. lbs.).
3. Fan shroud.
1 . Grille assembly.
Refer to SHEET METAL (SEC. 2B).

2. Fan harness connector (83).
3. Fan assembly (81) from the radiator support (80).
Bolts/screws (82).
|~n~| Install or Connect (Figure 35)
1. Fan assembly (81) to the radiator support (80).
Bolts/screws (82).
A. 4.8L L 6 E n g in e
B. 4.3 V 6 , 5.0/5.7L
V 8 E n g in e s (N o t G Van)
C. 4.3 V 6 , 5.0/5.7 L -------------V 8 E n g in e s
D. 7.4L V 8 E ngine
40. A d ju s tm e n t B o lt
41. Pivot B o lt
42. Brace
43. S u p p o rt
B-08090
Figure 20Air Conditioning Compressor Adjustment

Tighten
Bolt/screw (82) to 6 N m (53 ft. lbs.).
2. Fan harness connector (83).
3. Grille assembly.
Refer to SHEET METAL (SEC. 2B).
WATER PUMP REPLACEMENT

4.8L ENGINE
Refer to Drive Belt Replacement.
2. Fan (73) and fan clutch (74) (figure 36).
Nuts (75).
3. Water pump pulley (70).
Pulley off the water pump studs (71), but do
not damage the threads.
4. Lower radiator hose and the heater hose from the

water pump (91).
5. Water pump (91) from the engine block (figure 36).
Bolts (92, 93), and gasket (94).
Loosen the generator adjusting bolt to allow
the brace to be moved away on vehicles where
the brace will inhibit water pump removal.
++

Clean the mating surfaces on the water pump and
the engine block.
Water pump (91) to the engine block (figure 36).
New gasket (94) onto the water pump (91).
Place the generator adjusting brace back into
position if moved.
Bolts (92 and 93).
Tighten
Bolts (92 and 93) to the Specifications at the
2. Lower radiator hose and the heater hose to the
water pump (91).
Figure 21Air Conditioning and A.i.R. Pump Adjustment (R/V, G and P)
DIESEL
DIESEL
B-08092
Figure 22Drive Belt Adjustment - 6.2L Engine (R/V, G and P)
A.
B.
C.
50.
51.
52.
53.
54.
1st Track
2nd Track
3rd Track
W a te r P um p P ulley
C ra n k s h a ft P ulley
G e n e ra to r P ulley
A.I.R. P um p P ulley
Pow er S te e rin g P um p
P ulley
55. A ir C o n d itio n in g
C o m p re s s o r P ulley
55
B-08093
Figure 23Engine A cce sso ry D rive - R/V (4.8L Engine)
3. Water pump pulley (70), fan (73), and fan clutch (74)
on the water pump hub.
Tighten
Nuts (75) to 25 N m (18 ft. lbs.).

4. Drive belts and adjust.
6 . Start the engine and run, with the radiator cap
removed, until the radiator upper hose ( 12 ) becomes
hot (thermostat is open).

7. Add coolant to the radiator until the level reaches
the bottom of the filler neck.
Engine must be running at idle speed.
8 . Radiator cap, making sure the arrows line up with
the overflow tube.
4.3L, 5.0L 5.7L AND 7.4L ENGINES

39)
Refer to Drive Belt R eplacem ent.
2. Fan (73), the fan clutch (74), and the pulley (70) from
the water pump (91).
Nuts (75).
3. Generator lower brace attaching bolts and swing the
brace down and out of the way.
4. Generator upper brace attaching bolts.
5. Lower radiator hose and heater hose from the water
pump (91).
On the 7.4L engine, remove the bypass hose.
6 . Water pump (91) from the engine block.
Bolts (92, 93) and studs (95).
Install or Connect (Figures 36, 37, 38 and 39}

Clean the mating surfaces on the water pump and
the engine block.
50
A.
B.
C.
D.
50.
51.
52.
53.
54.
1st Track
2nd Track
3rd Track
4 th Track
W a te r Pum p P ulley
C ra n k s h a ft P u lle y
A.I.R. P um p P u lle y
P ow er S te e rin g
P um p P ulley
C o m p re s s o r P u lle y
Figure 24Engine Accessory Drive - 4.3L, 5.0L, 5.7L and 7.4L (R/V)
4------54
A.
B.
C.
D.
50.
1st Track
2nd Track
3rd Track
4th Track
51.
52.
53.
54.
55.
P ow er S te e rin g P u m p P ulley
A ir C o n d itio n in g C o m p re s s o r P ulley
Figure 25Engine Accessory Drive - Heavy Duty Emissions - 5.7L Engine (R/V)
B-08095
A.
B.
C.
50.
51.
52.
53.
54.
1st Track
2nd Track
3rd Track
W a te r P um p P u lle y
Pow er S te e rin g
Pum p P ulley
B-08096
Figure 26Engine Accessory Drive - Federal Emissions - 7.4L Engine (R/V)

1. Water pump (91) to the engine block.
New gaskets (94).
Place the pump against the block and retain it
with bolts (92, 93 and 95).
Tighten
Bolts (92 and 93) and studs (95) to the
Specifications.
2. Lower radiator hose and the heater hose to the
water pump (91).
Bypass hose with 7.4L engine.
3. Generator upper and lower braces to the water
pump (91).
4. Water pump pulley (70), fan (73) and fan clutch (74)
to the water pump hub.
Nuts (75).
Tighten
Nuts (75) to 25 N m (18 ft. lbs.).
5. Accessory belt drive and adjust.
Refer to Belt Drive Replacem ent.

removed, until the radiator upper hose (12) becomes
8. Add coolant to the radiator until the level reaches
9. Radiator cap, making sure the arrows line up with
the overflow tube.
6.2L ENGINE
R e m o v e o r D is c o n n e c t (F ig u re 40)
1. Fan.
Refer to Fan And Fan Clutch Replacem ent.

2. Fan shroud.
3. Air conditioning hose bracket nuts.
4. Oil fill tube.
5. Generator drive belt.
54
B.
C.
50.
51.
2nd Track
3rd Track
52.
53.
54.
55.
P ow er S te e rin g P um p P ulley
A ir C o n d itio n in g C o m p re s s o r P u lle y
Figure 27Engine Accessory Drive - California Emissions - 7.4L Engine (R/V)
B-08097
50
.51
56
55
50
A.
B.
C.
D.
50.
51.
52.
53.
54.
1st Tract
2nd Track
3rd Track
4 th Track
P um p P ulley
56. Id le r Pulley
54
B-09164
Figure 28Engine Accessory Drive - 5.7L and 6.2L Engines - V-Belt (G)
B.
C.
D.
50.
2nd Track
3rd Track
4th Track
51. C ra n k s h a ft P u lle y
52. G e n e ra to r P u lle y
53. A.I.R. P um p P u lle y
54.
55.
56.
A ir C o n d itio n in g C o m p re s s o r P ulley
Id le r P u lle y
Figure 29Engine Accessory Drive - Heavy Duty Emission - 5.7L Engine - V-Belt (G)
F-00911
A.
B.
C.
50.
51.
52.
53.
54.
1st Track
2nd Track
3rd Track
W a te r Pum p P u lle y
G e n e ra to r P u lle y
P u m p P ulley
F-00912
Figure 30Engine Accessory Drive - (P) 4.8L Engine
6.
7.
8.
9.
10.
11.
12.
Generator pivot bolt.

Power steering belt.
Refer to Drive Belts Replacement.
Air conditioning compressor belt, if equipped.
Refer to Drive Belts Replacement.
Bypass hose and the lower radiator hose.
Water pump (91) (figure 44).
Bolts (96 and 97), water pump plate (99) and
the water pump (91).
Water pump plate (99) from the water pump (91).
Bolts (92 and 93) and the gasket (94).
In s ta ll o r C o n n e c t (F ig u re 40)
Flanges must be free of oil. Clean the mating

surfaces on the water pump, both sides of the water
pump plate, and the engine block.
1. Water pump (91) to the water pump plate (99).
Gasket (94) and bolts (92 and 93).
Tighten
Bolts (92 and 93) to Specifications.
2. Water pump (91) to the engine block.
Apply anerobic sealer #1052357 or equivalent.
The sealer must be wet to the touch when the
bolts are tightened.
Bolts (96 and 97).
Tighten
Bolts (96 and 97) to Specifications.
3. Bypass hose and lower radiator hose.
4. Power steering pump.
5. Generator in place.
6. Drive belts and adjust.
Refer to Drive Belts R eplacem ent.
7. Oil fill tube.
8. Fan shroud.
9. Fan (73) assembly.
Refer to Fan And Fan Clutch R eplacem ent.
11. Start the engine and operate with the radiator cap
removed until the radiator upper hose (12) becomes
12 Add coolant to the radiator until the level reaches
13. Radiator cap, making sure the arrows line up with
the overflow tube.
56
55
A.
B.
C.
D.
50.
51.
52.
53.
54.
1st Track
2nd Track
3rd Track
4th Track
P u m p P ulley
56. Id le r P ulley
F-00913
Figure 31Engine Accessory Drive - Heavy Duty Emissions - 5.7L Engine (P)
1st Track
2nd Track
3rd Track
W a te r P um p
Pow er S te e rin g
Pum p P ulley
A.
B.
C.
50.
51.
52.
53.
54.
F-00914
Figure 32Engine Accessory Drive - 7.4L Engine (P)
G 4.3L, 5.0L and 5.7L Serpentine Accessory Drive

F-02581
Figure 33Engine Accessory Drive - Serpentine Drive, 4.3L, 5.0L and 5.7L Engine (G)
70.
71.
72.
73.
74.
75.
76.
77.
S tud
B o lt
Fan
Fan C lu tc h
N ut
W a te r P um p
A. Y ellow P aint M arks F o r P ro pe r

A lig n m e n t O f T he Fan C lu tc h
H ub To The W a te r P u m p H ub
Figure 34Fan and Fan Clutch Installation
Figure 35Auxiliary Cooling Fan Installation
F-00921
90. E n g in e B lo c k
91. W a te r Pum p
F-00924
Figure 37Water Pump Replacement - 4.3L Engine
Figure 39Water Pump Replacement - 7.4L Engine
Figure 40Water Pump Installation - 6.2L Engine
SPECIFICATIONS
DRIVE BELT TENSION SPECIFICATIONS
Generator
Power Steering
Pump
Air Conditioning
Compressor
A.I.R.
Pump
Before Operating The Engine (New Belt)
750 N (169 lb.)
750 N (169 lb.)
750 N (169 lb.)
750 N (169 lb.)
After Operating The Engine (Old Belt)
400 N (90 lb.)
400 N (90 lb.)
400 N (90 lb.)
400 N (90 lb.)
600 (135 lb.)
650 N (146 lb.)
750 N (169 lb.)
650 N (146 lb.)
400 N (90 lb.)
300 N (67 lb.)
400 N (90 lb.)
300 N (67 lb.)
600 N (135 lb.)
650N (146 lb.)
750 N (169 lb.)
650 N (146 lb.)
Tension Requirement
Engine
4.8L
L6
4.3L V6
5.0L
V8
5.7L V8
7.4L
V8
6.2L V8
(Diesel)
400 N (90 lb.)
300 N (67 lb.)
400 N (90 lb.)
300 N (67 lb.)
600 N (135 lb.)
650 N (146 lb.)
750 N (169 lb.)
650 N (146 lb.)
400 N (90 lb.)
300 N (67 lb.)
400 N (90 lb.)
300 N (67 lb.)
600 N (135 lb.)
650 N (146 lb.)
650 N (146 lb.)
*650 N (146 lb.)
400 N (90 lb.)
400 N (90 lb.)
400 N (90 lb.)
*400 N (90 lb.)
650 N (146 lb.)
650 N (146 lb.)
750 N (169 lb.)
300 N (67 lb.)
300 N (67 lb.)
400 N (90 lb.)
* When equipped with a right hand mounted pump and/or Federal Emissions (NAS) ONLY.
DO NOT exceed the New Belt tension specification when tensioning any belt, especially a used belt.
ACCESSORY DRIVE COMPONENT TORQUE SPECIFICATIONS

Fastener Name
4.8L L6
4.3L V6
5.0L V8
5.7L V8
6.2L V8
7.4L V8
Generator
Adjustment Bolt
25 N m
(18 ft. lbs.)
25 N-m
(18 ft. lbs.)
25 N-m
(18 ft. lbs.)
25 N-m
(18 ft. lbs.)
27 N-m
(20 ft. lbs.)
*25 N-m
(18 ft. lbs.)
Generator
Pivot Bolt
23 N m
(17 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
43 N-m
(32 ft. lbs.)
50 N-m
(37 ft. lbs.)
Power Steering Pump

Adjustment Bolt
43 N-m
(32 ft. lbs.)
33 N-m
(24 ft. lbs.)
33 N-m
(24 ft. lbs.)
33 N-m
(24 ft. lbs.)
43 N-m
(32 ft. lbs.)
88 N-m
(65 ft. lbs.)
Power Steering Pump

Pivot Bolt
24 N m
(17 ft. lbs.)
33 N m
(24 ft. lbs.)
33 N-m
(24 ft. lbs.)
33 N-m
(24 ft. lbs.)
43 N-m
(32 ft. lbs.)
50 N-m
(37 ft. lbs.)
Air Conditioning Condenser

Adjustment Bolt
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
Air Conditioning Condenser

Pivot Bolt
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N m
(25 ft. lbs.)
34 N-m
(25 ft. lbs.)
34 N m
(25 ft. lbs.)
Air Injection Reactor (A.I.R.)

Pump Adjustment Bolt
25 N m
(18 ft. lbs.)
25 N-m
(18 ft. lbs.)
25 N-m
(18 ft. lbs.)
**2 5 N-m
(18 ft. lbs.)
33 N-m
(24 ft. lbs.)
Air Injection Reactor (A.I.R.)

Pump Pivot Bolt
24 N-m
(17 ft. lbs.)
24 N-m
(17 ft. lbs.)
24 N-m
(17 ft. lbs.)
**2 4 N-m
(17 ft. lbs.)
33 N-m
(24 ft. lbs.)
* For P series vehicles, torque is 64 N m (47 ft. lbs.) with the K97 Generator.
** For the 5.7L V8 with Federal Emissions (RPO NA5), torque is 50 N m (37 ft. lbs.)
THERMOSTAT AND RESERVOIR RELATED TORQUE SPECIFICATIONS
Fastener Name
R/V
10/1500
R/V
20/2500
R/V
30/3500
G
10/1500
G
20/2500
G
30/3500
Coolant Recovery Tank

Bolt/Screw
2 Nm
2 Nm
2 Nm
2 N-m
2 Nm
2 Nm
(18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.)
Deaeration Tank Bolts/

Screws And Nuts
5 Nm
5 Nm
5 Nm
(44 in. lbs.) (44 in. lbs.) (44 in. lbs.)
Water Outlet To The

Thermostat Housing Bolts
*2 7 N m
(20 ft. lbs.)
*2 7 N m
(20 ft. lbs.)
Thermostat Crossover
To The Engine Bolts
(6.2L Diesel ONLY)
47 N m
(35 ft. lbs.)
Water Outlet To The

Thermostat Housing
Bolts (6.2L Diesel ONLY)
47 N m
(35 ft. lbs.)
P
20/2500
P
30/3500
10 N m
(88 in. lbs.)
17 N-m
(12 ft. lbs.)
*2 7 N m
(20 ft. lbs.)
*2 7 N m
(20 ft. lbs.)
*2 7 N m
(20 ft. lbs.)
*2 7 N-m
(20 ft. lbs.)
*2 7 N-m
(20 ft. lbs.)
*2 7 N-m
(20 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
47 N-m
(35 ft. lbs.)
* On vehicles with a 6.2L Diesel, torque to 47 N m (35 ft. lbs.)

On vehicles with a 7.4L V8, torque to 41 N m (30 ft. lbs.)
SPECIAL TOOLS
J-23600-B
1. U niversal V -B elt Tension G age

F-02615
RADIATOR 6B2-1
SECTION 6B2
RADIATOR
CONTENTS
SUBJECT
PAGE
Description................................................................................................................................................................... 6B2- 1
Radiator Maintenance................................................................................................................................................ 6B2- 5
On-Vehicle S e rvice .................................................................................................................................................... 6B2- 6
Fan Shroud Replacement...................................................................................................................................... 6B2- 6
Radiator Replacement............................................................................................................................................ 6B2-10
Pressure C a p ...........................................................................................................................................................6B2-13
Coolant Recovery System...................................................................................................................................... 6B2-14
Surge T a nk...............................................................................................................................................................6B2-15
Aluminum Radiator R epair........................................................................................................................................ 6B2-15
Description...............................................................................................................................................................6B2-15
D ia g no sis................................................................................................................................................ ................ 6B2-15
Aluminum Radiator S e rv ic e ..................................................................................................................................6B2-17
S p e cifica tio n s.............................................................................................................................................................6B2-22
Special T o o ls ...............................................................................................................................................................6B2-23
DESCRIPTION
The radiator in the R/V, G and P series vehicles is a
crossflow tube and center type. Refer to figures 1 through
4.
All radiators are fitted with a shroud designed to assist
the fan in directing air flow through the radiator core and
to also serve as a fan guard. Provision for coolant expan
sion is achieved with a coolant recovery tank. This retards
coolant overflow, and reduces frequent refills.
Pressure is maintained in the radiator and system by a

pressure cap. The pressure cap has two valves; one re
lieves excessive pressure and the other compensates for
coolant contraction when the engine is stopped. Radiator
caps are provided in 105 kPa (15 psi) rating on all models.
6B2-2 RADIATOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
S u p p o rt
R a d ia to r
F ille r C ap
U p p e r In s u la to r
U p p e r Panel
U -Shaped N u t
S h ro u d B ra cke t
S crew
U p p e r S h ro u d
L ow er S h rou d
H ose
R e se rvo ir C ap
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
R ese rvo ir
W orm C la m p
D rain C o c k
L ow er In s u la to r
B o lt
W a sh er
S u p p o rt B ra cke t
C u s h io n R e ta in e r
N ut
24.
25.
26.
27.
End Panel
S u p p o rt
R ig h t B a ffle
N ut
B-07687
Figure 1R/V Radiator Mounting and Related Parts (Typical)
RADIATOR 6B2-3
39
2.
3.
4.
9.
10.
12.
13.
15.
31.
32.
33.
34.
37.
38.
39.
40.
41.
42.
43.
44.
R a d ia to r
F ille r C ap
In s u la to r
U p p e r S h rou d
L ow er S h ro u d
R e se rvo ir
R e se rvo ir C ap
D rain C o c k
Panel
U p p e r B ra cke t
L o w e r Pad
S cre w
R e se rvo ir H ose
In le t H ose
C la m p
O u tle t H ose
B o lt
J N ut
S crew
C lip
12
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
59.
60.
61.
62.
64.
65.
13
37
55
S cre w
S crew
In s u la to r
M o u n tin g B ra c k e t
C ro s s S ill
R ig h t Panel
S crew
U N ut
E x te n s io n
B o lt
S cre w
Tank B ra cke t
S u rge Tank
H ose
In le t H o se
H o se N ip p le
C la m p
H ex B o lt
H ex N u t
B-07686
Figure 2G Radiator Mounting and Related Parts (Typical)
6B2-4 RADIATOR
C lip
L ow er Panel
W a sh er
E va po rato r H ose
In le t H o se
S u rge Tank
P ressure C ap
Tank B ra cke t
Tank C la m p
R a d ia to r
F ille r C ap
In s u la to r
S crew
U p p e r S h ro u d
L ow er S h ro u d
D rain C o c k
N ut
C la m p
F ille r Tube
F ille r H ose
U p p e r Panel
B o lt
3 71
86
B race
W a sh e r
82
23 77
74 84
40
V J f e i e7 7
B-07685
Figure 3P(32) Radiator Mounting and Related Parts (Typical)
RADIATOR 6B2-5
2. R adiator
3. F ille r Cap
9. Upper Shroud
Lower Shroud
Reservoir Cap
Reservoir
Drain C ock
Insulator
B olt
C lam p
Support
Brace
93.
94.
95.
96.
97.
98.
99.
100.
102.
103.
105.
Panel
Upper Panel
Hose
Screw
W asher
N ut
W asher
Bracket
Push N ut
Bracket
Retainer
B-07684
Figure 4P(42) Radiator Mounting and Related Parts (Typical)
RADIATOR MAINTENANCE
Check the outside of the radiator for bent fins, or signs
of leakage. Repair leaking radiator cores. Do not seal tem
porarily with a sealer type antifreeze or coolant additive.
Remove any stones between the fins. Clean loose debris
and road film from the radiator core with a quality grease
solvent and compressed air. Direct the stream of solvent
at the front of the core for more efficient cleaning.
To insure a thorough cleaning, remove the grille, fan
guard, and fan shroud.
Remove the radiator cap and look for plugging and
scale on the inside of the tank. Replace a badly plugged
radiator. Test the radiator and system as described in EN
GINE COOLING (SEC. 6B1).
1. Check the coolant level. If low, add recommended
coolant as required.
2. Check the hose connections and tighten the clam ps
if leakage is evident. Replace cracked, stripped, or
corroded clamps.
3. Check the coolant hoses for spongy or checked ap

pearance. Replace deteriorated hoses or bursting
could occur which would result in coolant loss and
extensive engine damage due to overheating.
4. Check the radiator core for leaks and for accum ula
tion of dirt which may obstruct the air passages and
reduce heat transfer.
5. Check the surge tank or recovery tank for leaks.
Plastic bottles may develop cracks for being dam
aged by flying objects. Check metal tanks at the
weld seams.
6. Inspect the radiator rubber m ountings and bum pers
for deterioration and replace as necessary. Check
the mounting bolts, supports, braces, tie rods, and
stabilizer rods. Components should be securely fas
tened in place if m ounting bolts are m issing, loose,
or stripped. Also check for damage to the core, side
flanges, and supporting components.
6B2-6 RADIATOR
7. Check for clearance between the fan blades, core,
and shroud. Check the fan attaching bolts for tight
ness and that none are missing. Replace the fan if
any blade is bent. The distance between the blades
and shroud should be equal around the perimeter of
the shroud. Adjust as necessary after any adjust
ment has been made to the fan or the fan mounting
bracket and hub.
8. Inspect the filler cap seal for evidence of cracking,
separation, or deterioration. Replace as required.
9. To assist in m aintaining efficient heat dissipation, an
occasional external flushing with water will remove
the majority of dirt accum ulation and foreign matter
from between core fins. Direct water under moder
ate pressure from behind the core to force debris
out in the opposite direction of its entry. Direct the
water stream in line with the fins to reduce the pos
sibility of bending fins.
RADIATOR INTERNAL DEPOSITS

A radiator that has a dirty, obstructed core or is leaking
will cause the engine to overheat. A scale deposit inside
the radiator is a result of using hard, high mineral content
water in the cooling system. The effect of heat on the
minerals in the water causes the formation of scale, or
hard coating, on m etal surfaces w ithin the radiator,
thereby reducing the transfer of heat. Some hard water
will produce a silt-like deposit which restricts the flow of
water. This must be flushed out at least twice a year
more often if necessary.
SCALE REMOVAL
To remove the hardened scale, a direct chem ical action
is necessary. A flushing compound at the specified rate of
30 grams per liter (4 oz. per gallon) of radiator capacity,
should be added to the coolant water in the form of a
dissolved solution while the engine is running. Operate
the engine for 15 minutes, then drain and flush the system
with clean water.
T he re are v a rio u s typ e s of flu s h in g c o m p o u n d s
comm ercially available and should be obtained from a
reliable source. Most com pounds attack m etals and
should not remain in the engine for more than a few
minutes. Use a neutralizer after a descaling solvent is
used.
For extremely hard, stubborn coatings, such as lime
scale, use a stronger solution. The corrosive action of a
stronger solution will affect the thin metals of the radiator,
thereby reducing its operating life. A complete flushing
and rinsing is mandatory and must be accom plished
skillfully.
After using the solvent and neutralizer and flusing the
cooling system, drain the system and fill it with clean, soft
water plus a rust inhibitor or high boiling point type
antifreeze. After filling the cooling system, check for
radiator, hose, and engine coolant leaks.
ON-VEHICLE SERVICE
FAN SHROUD REPLACEMENT
R/V VEHICLES

1. Fan shroud to radiator retainer attaching bolts (60).
2. Fan clutch to water pump hub attachments.
3. Fan shroud assembly (61 and 64).
Pull up and out of the lower retaining clips.
The fan shroud and fan clutch assembly must
be removed together.
G AND P VEHICLES
|+ + | R e m o v e o r D is c o n n e c t (F ig u re s 2, 3, 4, 7, 8, 9
a n d 10)
1. Vacuum reservoir, if equipped with air conditioning.
2.
3.
4.
5.
6.
7.
8.

Lower fan shroud (64) and the fan clutch.
Position along the back of the radiator (63).
Make sure the lower edge fits into the lower
retaining clips.
Fan clutch to water pump hub attachments.
Shroud (61) to the radiator retainer attaching bolts
(60).
Tighten
Bolts (60) to 6 N m (53 in. lbs.)
9.

Windshield washer jar and its bracket.
Fan shroud retaining bolts (60).
Radiator support bracket (67).
Dipstick from the engine.
D ipstick from the autom atic tra nsm ission, if
equipped.
Radiator hose strap from the fan shroud (61).
Fan from the water pump.
Leave the pulley in place.
Refer to ENGINE COOLING (SEC. 6B1) in this
section.
Fan and the fan shroud together.

1. Fan and the fan shroud together.
2. Fan to the water pump.
Refer to ENGINE COOLING (SEC. 6B1) in this
section.
3. Radiator hose strap to the fan shroud.
4. D ipsticks into the engine, and tra n sm issio n if
applicable.
5. Radiator support brace (67).
RADIATOR 6B2-7
Figure 5Fan Shroud 4.3L, 5.0L and 5.7L Engines (R/V)
A.
B.
60.
63.
65.
66.
69.
100.
7.4L E n g in e Fan S h rou d

6.2L E n g in e Fan S h ro u d
B o lt
R a d ia to r
C lip N u t
Fan S h rou d
R a d ia to r M o u n tin g Panel
Figure 6Fan Shroud 6.2L and 7.4L Engines (R/V)
F-02558
6B2-8 RADIATOR
60.
61.
62.
63.
64.
65.
67.
B o lt
7 T
U p p e r Fan S h ro u d
In s u la to r
_
R a d ia to r
L ow er Fan S h rou d
C lip N ut
R a d ia to r M o u n tin g B ra cket
Figure 7Fan Shroud 4.3L Engine (G)

Bolts (60).
Tighten

6. Fan shroud retaining bolts (60).
Tighten
Bolts (60) to 6 N-m (53 in. lbs.).
Bolts (60) for 4.3L engine to 27 N-m (20 ft.
lbs.).
7. W indshield washer jar and its bracket.
8. Vacuum reservoir, if equipped with air conditioning.
G AND P VEHICLES 6.2L ENGINE

Remove or Disconnect (Figures 2, 3, 4, 8 and
10)
1. Air cleaner intake.
Rotate the snorkel up.
60.
61.
63.
64.
B o lt
U p p e r Fan S h rou d
R a d ia to r
L ow er Fan S h rou d
65. C lip N ut
67. R a d ia to r M o u n tin g
2. Fan shroud bolts (60).

3. Hood latch cable.
4. W indshield washer bottle.
5. Upper fan shroud (61).
B ra cket
F-00918
Figure 8Fan Shroud 5.0L, 5.7L and

6.2L Engines (G)

1. Upper fan shroud (61).
Bolts (60).
RADIATOR 6B2-9
A. Fan S h ro u d F o r 4.8L L6 O r 5.7L V8
(H eavy D u ty E m is s io n s ) E n gin e
B. Fan S h ro u d fo r T he 5.7L V8 (H eavy D u ty
E m is s io n s ) E n g in e W ith A ir C o n d itio n in g
60.
61.
63.
64.
65.
66.
67.
68 .
69.
B o lt
R a d ia to r
L o w e r Fan S h rou d
C lip N u t
R a d ia to r M o u n tin g B ra cke t
C lip
C o m p le te Fan S h ro u d
B
F-00919
Figure 9Fan Shroud 4.8L and 5.7L Engines P(42)
60.
61.
63.
64.
65.
B o lt
R a d ia to r
L o w e r Fan S h rou d
C lip N ut
66 . R a d ia to r S u p p o rt
68 . C lip
A. P(32) S e rie s V e h ic le s Fan S h ro u d

B. P(42) S e rie s V e h ic le s Fan S h rou d
F-00920
Figure 10Fan Shroud 6.2L and 7.4L Engines (P-32 and 42)
6B2-10 RADIATOR
Tighten
Bolts (60) to 6 N m (53 in. lbs.).
3. Hood latch cable.
4. Fan shroud bolts (60).
Tighten
Bolts (60) to 6 N m (53 in. lbs.).
5. Air cleaner intake.
RADIATOR REPLACEMENT
The type of radiator core mounting varies according to
model and engine type. Radiator assembly includes a
shroud and may include an oil cooler in the core. Some
m odels have a se pa ra te pow er ste ering oil co oler
attached in front of the radiator core. On models so
equipped it may be necessary to remove the oil cooler to
facilitate removal of the radiator core. Refer to POWER
STEERING (SEC. 3B3) in this m anual for oil cooler
removal and installation.
R/V, G, AND P VEHICLES (4.3L, 4.8L, 5.0L

5.7L AND 7.4L ENGINES)
Remove or Disconnect (Figures 11,12 and 13)
Radiator hoses from the radiator.
Radiator inlet hose and radiator outlet hose.
Overflow hose from the radiator.'
Fan shroud.
Refer to Fan Shroud Replacem ent.
4. Transmission cooler lines.
Retainers from the radiator support.
Retainers from the upper mounting panel on
R/V series vehicles.
-<- Install or Connect (Figures 1 1,1 2 and 13)

1. Radiator on the vehicle.
R ad iato r su p p o rt on the upper m ounting
panel.
Tighten
Fasteners to the Specifications.
2. Transmission cooler lines.
3. Fan shroud.
Refer to Fan Shroud R eplacem ent.
4. Overflow hose to the radiator.
5. Radiator hoses to the radiator.
Radiator inlet hose and radiator outlet hose.
Refer to the vehicle O w ners Manual.
7. Remove the radiator pressure cap, start the engine,
and let it run until the upper radiator hose becomes
hot therm ostat is open.
8. Add coolant, with the engine running at idle speed,
neck.
9. Install the radiator pressure cap, making sure the
R/V VEHICLES (6.2L ENGINE)

Remove or Disconnect (Figures 11,12 and 13)
1. Fan shroud.
2. Engine and transm ission oil cooler lines.
3. Upper radiator hose and lower radiator hose from
the radiator.
4. Overflow hose from the radiator.
5. Upper radiator supports.

Radiator to the vehicle.
Radiator supports and/or m ounting panel.
Tighten
4. Upper radiator hose and lower radiator hose to the
radiator.
5. Engine and transmission oil cooler lines.
6. Fan shroud.
8. Remove the radiator pressure cap, start the engine,
and let it run until the upper radiator hose becomes
hot therm ostat is open.
neck.
G AND P VEHICLES (6.2L ENGINE)

|<"+| Remove or Disconnect (Figures 11, 12 and 13)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Air intake snorkel.
W indshield washer bottle.
Hood release cable.
Upper fan shroud.
Upper radiator hose from the radiator.
Transmission cooler lines from the radiator.
Low coolant sensor.
Overflow hose from the radiator.
Engine oil cooler lines from the radiator.
Raise the vehicle.
Lower radiator hose from the radiator.
Lower the vehicle.
Master cylinder from the booster.
Refer to BRAKES (SEC. 5A1).
Radiator from the vehicle.
-+ Install or Connect (Figures 11, 12, and 13)

1. Radiator into the vehicle.
Tighten
2. Master cylinder to the booster.
Refer to BRAKES (SEC. 5A1).
RADIATOR 6B2-11
Figure 11Radiator installation R/V, G and P(42)
6B2-12 RADIATOR
Figure 12Radiator Installation P(32)
RADIATOR 6B2-13
A. R a d ia to r M o u n tin g F or C-K S e rie s W ith 4.8L L6 (Exc. C60), P(42) S e rie s W ith 4.8L L6 A n d 5.7L V8
B. R a d ia to r M o u n tin g F or C-K S e rie s W ith 4.8L L6 W ith C60
C. R a d ia to r M o u n tin g F or C-K A n d G S e rie s W ith 4.3L V6
D. R a d ia to r M o u n tin g F or C-K S e rie s W ith 5.0L, 5.7L; G S e rie s (Exc. 4.3L V6); P(42) S e rie s W ith 5.7L
V8
E. R a d ia to r M o u n tin g F o r C-K S e rie s W ith 7.4L V8, 6.2L D iese l; P(42) S e rie s W ith 7.4L V8, 6.2L D iesel
60.
61.
62.
63.
64.
B o lt
In s u la to r
R a d ia to r
L ow er Fan S hroud
65. C lip N ut
67. R a d ia to r M o u n tin g B ra cke t
68.
69.
100.
101.
102.
C lip
C o m p le te Fan S h ro u d
R a d ia to r M o u n tin g Panel
R a d ia to r U p p e r M o u n tin g Panel
R a d ia to r L ow er M o u n tin g Panel
103.
104.
105.
106.
107.
108.
109.
W a sh e r
N ut
W a sh er
N ut
In s u la to r
E x te n s io n A s s e m b ly
R a d ia to r S u p p o rt B race
F-00936
Figure 13Radiator Installation Legend

4. Lower radiator hose to the radiator.
6. Engine oil cooler lines to the radiator.
8. Low coolant sensor.
9. Transmission oil cooler lines to the radiator.
10. Upper radiator hose to the radiator.
12. Hood release cable.
14. Air intake snorkel.
16. Remove the radiator pressure cap, start the engine
and let it run until the upper radiator hose (12)
becomes hot therm ostat is open.
neck.
PRESSURE CAP
The pressure relief valve assembly, integral
filler cap, incorporates a pressure valve and a
valve (figure 14). When pressure in the system
the valve setting, the pressure valve opens and
allowed to escape.
with the
vacuum
reaches
vapor is
6B2-14 RADIATOR
B-02682
Figure 15Testing The Radiator Cap

As liquid in the system cools it contracts; this allows the
pressure valve to close and also creates a partial vacuum
in the system. Atm ospheric pressure acting through the
overflow tube unseats the vacuum valve and allows air to
enter the system. The overflow pipe connects to the valve
outside the valve seal; thus no liquid or air can escape
from the system when both valves are in the closed
position.
4. F ille r N e c k S a fe ty D e te n t
T h e ra d ia to r f ille r c a p is c o n s tru c te d w ith a

spring-loaded rubber seal which is pressed firm ly against
the surface of the fille r neck seat when the cap is
installed. The rubber seal must be in good condition and
the top of the radiator filler neck must be clean and
smooth to form an airtight seal. The seal of the filler cap
and the operation of the pressure relief valve can be
checked using a conventional cooling system testing kit
(figure 15).
When the engine is at normal operating temperature or
above, the internal pressure buildup in the cooling system
will blow out scalding fluid and vapors if the radiator cap
is suddenly removed. To prevent loss of coolant and the
danger of being burned check or add coolant when the
engine is cool. If the cap must be removed when the
engine is hot, place a cloth over the cap and rotate the
cap slow ly counterclockw ise to first stop and allow
pressure to escape. The cap and filler neck meet at right
angles in a safety detent position. The cap locking tank is
flat and the filler neck has a straight tab (figure 16). To
turn the cap beyond this point and remove the cap, the
cap must be pressed down to clear the safety detent and
turned counterclockwise.
B-02709
Figure 16Radiator Cap and Filler Neck
COOLANT RECOVERY SYSTEM

The coolant recovery system consists of a reservoir,
pressure cap, and interconnecting hose.
Maintain the coolant level between the HOT LEVEL
and COLD LEVEL markings on the tank. Refer to
figures 1, 2, 3 and 4.
The pressure cap is sim ilar to the radiator filler cap but
has a gasket (figure 17). This gasket forms a seal at the
radiator filler neck. A leak at this gasket will result in loss
2.
3.
4.
5.
P re s s u re V alve S p rin g
P re s s u re V alve
V a c u u m V alve
G asket
B-03467
Figure 17Coolant Recovery System Pressure Cap
RADIATOR 6B2-15
of coolant during normal operation. Install the pressure
cap so that the m arkings on top of the cap align with the
overflow tube on the filler neck (figure 18).
SURGE TANK
The tank serves as a coolant reservoir for the radiator
core. Hoses and pipes connect the tank to the radiator
and water pump. The surge tank incorporates the cooling
system filler cap.
At regular intervals check the tank and connecting
hoses for leaks. Keep the hose clam ps and mounting
bolts tightened.
Check the mounting brackets and supports for cracks
and broken attaching parts. Check insulators and straps;
if deteriorated or loose from wear, replace.
ALUMINUM Rfi
DESCRIPTION
This radiator utilizes an aluminum core with plastic side
ta n ks. T h e co re and sid e ta n k s can be re p la c e d
separately and core repair is easily made with the hot
melt adhesive method. A transm ission oil cooler is located
in one of the side tanks. The oil coolers can be replaced.
The drain cock is located on the lower part of one of the
tanks. The drain cock is also serviceable.
IATOR REPAIR
TRANSMISSION OIL COOLER
Replace the oil cooler by removing the tank from the
core.
A leaking oil cooler gasket can be replaced w ithout
removing the tank from the core.
DRAIN COCK
The alum inum /plastic radiator utilizes a two piece
plastic drain cock and a rubber seal. The drain cock is
serviceable (figure 20).
CORE
The core is made of aluminum and is of the crossflow
design. It utilizes large tubes that resist plugging, and
repairs to the tubes and core are easily made using the
hot melt adhesive method.
The core is attached to the tanks by clinched tabs on
the core that can be bent back if tank or core replacement
is required.
If the damage to a tube is too severe, a tube can be
blocked or plugged as explained in Tube Blocking. No
more than two tubes should ever be blocked on a core.
Also replace the core if more than three tabs are broken
on one side or if two adjacent tabs are broken.
TANKS
The tanks are attached to the core by clinched tabs
attached to the sides of the core. The clinched tabs can
be bent back if the tanks need to be removed from the
core. Bend the tabs back only enough to remove the tank.
Overbending will weaken the tabs.
A high temperature rubber gasket is used to seal the
mating surface between the core and the tank (figure 19).
The gasket must be replaced any tim e a tank is removed
from the core.
DIAGNOSIS
LEAK TESTING
Some core leaks can be detected by adding water to
the radiator. Clean the core so that the damaged area can
be found.
1. Remove d irt and insects from the fin s w ith a
common water hose w ithout a nozzle. Excessive
water pressure could damage the fins.
2. Scrub the core with a soft-bristle brush using clean,
hot water or hot water with a mild detergent solution.
On-Vehicle Pressure Testing

You can pressure-test the alum inum -plastic radiator
with J-24460-01 with J-23699 (figure 21). W ith the system
at a cool temperature, remove the radiator cap, connect
the gage, and apply normal system operating pressure.
Do not exceed 138 kPa (20 psi). Watch the gage needle
for an indication of a leak, and examine the radiator and
other cooling system parts for escaping coolant.
Repair all hose and hose connections as required.
Check the radiator cap to ensure that it will maintain the
correct pressure.
If the radiator leaks during the pressure test, mark the
leak area.
6B2-16 RADIATOR
118
110.
111.
112.
113.
114.
115.
116.
117.
118.
C ore
O u tle t Tank
In le t Tank
S id e Tank G a ske t
E n g in e O il C o o le r (D iesel O nly)
T ra n s m is s io n O il C o o le r
C o o le r G a ske t
C o o le r R e ta in in g N u t
D rain C o c k
F-00937
Figure 19Aluminum Radiator Assembly

Off-Vehicle Leak Testing
NOTICE: Do not use boil-out tanks or vats or
other tanks that have been used for copper and
brass radiators. The flux, acid, and caustic
cleaners remaining in these tanks will attack the
aluminum and cause radiator failure. A separate
te s t ta n k c o n ta in in g c le a n
w a te r is
recom m ended for servicing alum inum/plastic
radiators.
1. Install test fittings or rubber test caps in the inlet and
outlet necks and seal the oil cooler fittings with
metal plugs to protect the cooler and keep the fluid
from running out (figure 22).
Figure 21Pressure Testing the Radiator
RADIATOR 6B2-17
2. Attach the pressure tester and gradually apply air

pressure until 138 kPa (20 psi) is attained. Do not
exceed 138 kPa (20 psi). Check the pressure gage
to see if there is a pressure loss. To ensure that
there are no small leaks, run water over the repair
area and look for bubbles. (A mild detergent is
helpful).
If a large water tank is available, submerge the
radiator and a check for air bubbles.
REPAIRABLE LEAKS
There are two types of leaks that can be repaired on the
alum inum -plastic radiator: core leaks and gasket leaks.
Leaks in the plastic tanks cannot be repaired (figure 23).
Core leaks can occur in a tube or in the joints between
the tubes and headers. Gasket leaks can occur in the
113A
121
113B
joints between the plastic tanks and the headers or in the

joints between the oil cooler fittings and the tank. Some
leaks can be repaired while the radiator is on the vehicle;
however, it is usually best to remove the radiator.
Repair Methods
There are several methods that can be used to repair
the radiator core, but the hot melt adhesive method is the
most effective.
The kit contains adhesive sticks, cotton swabs, a wire
brush and the primer. The adhesive stick is reusable, has
an indefinite shelf life and is waste-free. Store the in a
sealed container to keep them dry (figure 24).
ALUMINUM RADIATOR SERVICE

113A.
121.
113B.
118B.
122.
123.
The aluminum -plastic radiator can be repaired at the

d e a le rs h ip . The fo llo w in g c o m p o n e n ts are e a s ily
replaced:
In le t Tank G a ske t
C ore Tubes
O u tle t Tank G a sket
D rain C o c k G a sket
O il C o o le r G a ske ts
J o in t B e tw ee n Tube A n d H ea de r
Core
Tanks and gaskets
Oil coolers and gaskets
Drain cock and gasket
F-00941
Figure 23Possible Leak Areas
The tanks cannot be repaired if broken or cracked.

The radiator core can be replaced and the new core used
with the original tanks and oil cooler.
6B2-18 RADIATOR
PRECAUTIONS
As with all cooling system service, take measures to
prevent personal injury and damage to the system.
uuiyuuuui/miuuuuui>uuL/uuuuuui/uL/uuuuuuuui/i;uuiiuuui;ui/uuviyuuiiiiuuuuuuiiyiiui
CAUTION: To help avoid the danger of being

burned, do not remove the radiator cap while
the engine and radiator are still hot. Scalding
flu id and steam can be blown out under
pressure if the cap is taken off too soon.
NOTICE: DO NOT USE BOIL O U T TANKS OR
VATS. Common service methods may destroy
an aluminum radiator. Do not use caustic or lye
cleaning solutions for aluminum radiators. USE
CLEAN WATER WHEN SERVICING ALUMINUM
RADIATORS.
Do not open the hood if you can see or hear steam
or coolant escaping from the engine compartment.
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M M m m m m i p lllIf f llilH l
illiJ iJ M H B M m s E i u u m i i
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MlRUmUL llL llll u m im m u m m
ii m i i i i im i iim m iiim iM m
A. 6 m m (1/4-inch) Beyo n d M u iu i................
The D am aged Area
M M M /I/I/M A ,
F-00946
Figure 25Removing the Fins from a Damage Area
Do not remove the radiator cap if the radiator feels

warm.
Do not remove the radiator cap or coolant recovery
tank cap if the coolant in the recovery tank looks like
it is boiling.
Wear eye protection.
Wear gloves to protect your hands against excessive
heat or the effects of chem icals on your skin.
P re v e n t d ir t a nd w a te r
transm ission oil cooler.
fro m
e n te rin g
th e
Do not use boil-out tanks or vats or other tanks that

have been used for copper and brass radiators. The
flux, acid, and caustic cleaners remaining in these
tanks will attack the aluminum and cause radiator
failure. A separate test tank containing clean water
is recom m ended for servicing alum inum /plastic
radiators.
NOTICE: Never use shop air to pressure test
radiators that is not regulated at 138 kPa (20
psi). Pressures o ver 138 kPa (20 psi) w ill
damage the radiator.
Figure 26Tube Blocking

HEADER REPAIR
If the header or a tube near the header requires a
repair, the side tank does not have to be removed. Place a
damp cloth against the side tank where the repair has to
be made (figure 27). The side tank can be submerged in a
tank of water up to the header (figure 28).
SPECIAL PREPARATION
For damaged areas that are between the cooling fins, it
may be necessary to remove some of the fins. Do not
remove more fins than necessary. Usually 6 mm (1/4-inch)
beyond the leak or dam age area is enough to make an
effective repair (figure 25).
TUBE BLOCKING
If a tube is severely damaged, it can be blocked off
(figure 26).
NOTICE: Do not block off more than two tubes
in a radiator. Blocking off more than two tubes
will reduce the cooling capability of the system.
Cut the tube off 6 mm (1/4-inch) from the header and
pinch shut before it is cleaned and sealed. Refer to
General Core Sealing.
A. A p p ly W ith A W et C lo th
Figure 27Using A Wet Cloth to Cool the Side Tank
RADIATOR 6B2-19
Figure 30Scrubbing the Area with A Cotton Swab

A. S u b m e rg e The T ank K eep The H eader
A bove The W ater Lin e
B-00949
Figure 28Submerging the Side Tank

NOTICE: One of these procedures have to be
used when repairs are made on or near the
header to prevent damage to the tank or gasket.
CAUTION: The primer contains trichlorethane.

It could be harmful or fatal if swallowed. If
swallowed, get medical attention.
Use with adequate ventilation.
In case of eye contact, flush with water and
get medical attention.
In case of body contact, wash with soap
and water.
Do not mix the primer with water.
GENERAL CORE REPAIR

Preparation of the surface in the repair area cannot be
overemphasized. If the leak area surface is not clean,
none of the repair materials will stick to the surface.
6. Scrub the repair area with a cotton swab until a

fresh swab stays clean. The clear, yellow-brown
coating does not have to be removed (figure 30).
1. Position the core so the repair area is accessible.
7. Heat the repair area with a heat gun or by moving

the torch in a circular pattern (figure 31). Use a soft,
small blue flame (like a gas stove flame).
2. Apply a wet cloth if you are working near the plastic

tanks or the joints between the core tubes and
header (figure 27); or submerge the tank in water
(figure 28).
3. Heat the repair area slightly with a small torch or
heat gun to be sure it is dry. Do not use a blow
torch.
4. Brush the area to be repaired with the small steel
brush that is supplied in the kit and blow dust away
from the repair area (figure 29).
5. Open the tube of primer, using the spurred cap or a
pin, and apply prim er to the repair area only. Use of
the prim er produces a stronger repair. Do not heat
the primer.
Figure 29Cleaning the Repair Area with A

Steel Brush
8. W ithdraw the torch and rub the adhesive stick on

the repair area (figure 32). The adhesive will flow at
a temperature of approximately 260C (500F). If
the stick doesnt start to melt, remove it and reapply
the heat. Do not heat the stick directly with a
flame. High heat will burn and char the adhesive.

9. Continue heating until the adhesive flows and wets
the entire repair area and fills the joint. If a hole is in
the center of a tube, heat the tube and let the hot
surface melt and pull in the adhesive. The force of
the flame or heat gun will also tend to guide the
adhesive toward the hole. For leaks between a tube
and header, flow the adhesive around the tube and
header joint with the tank installed.
Figure 31Heating the Repair Area
6B2-20 RADIATOR
A. Touch T he A d h e s iv e To The H o t M etal f -00954
Figure 32Apply Hot Melt Adhesive to the

Repair Area
10. H e a t th e re p a ir a re a u n til th e a d h e s iv e is
bubble-free and smooth, with a light yellow color.
Curing is not required.
11. Test the radiator when cool. If the repair area still
leaks, reheat it gently to dry it. Heat and reflow the
adhesive or apply more as necessary to repair the
leak.
TANK GASKET LEAK REPAIR

Tank gasket leaks can be mistaken for tank or header
leaks. If a plactic tank leaks from the header joint gasket,
tighten the clinch tabs with locking-type pliers (figure 33).
If this method doesnt seal the leak, remove the tank for
further inspection.
1. Pry open the clinch tabs, except those under the
inlet, outlet, and filler necks, using J-33419-1 or a
screwdriver (figure 34). Lift the tabs only enough to
allow removal.
N O T IC E : Do n o t o v e rb e n d th e tab s .
Overbending could result in breakage. If there
are more than 3 tabs broken on one side of the
header, or more than 2 adjacent tabs together,
replace the core.
2. L ift the ta nk and slide it out from under the
remaining clinched tab. You may have to tap the
tank with your hand to dislodge the gasket. Lift the
remaining tab(s) with pliers.
3. Remove and discard the gasket.
4. Clean the header and gasket groove of all dirt and

old rubber.
5. Clean the sealing edge of the plastic tank.
6. Examine the header gasket surface and tank flange
for leakage, and clean or repair the surface to
remove dirt, burrs, and bumps.
7. Remove the oil cooler, if equipped, and install it in
the new tank, if used.
8. Dip or coat the new tank gasket in engine coolant
and position it on the header surface. The coolant
helps hold the gasket in place.
9. Position the tank and gasket to the header, clam p it
in place and secure it by bending four clinch tabs as
shown in figure 35.
10. Clamp remaining clinch tabs around the header
using the clinching tool or pliers (figure 36).
NOTICE: Tighten the clinch tabs by starting at
the center and working out to the ends.
11. Replace the core if there are more than three tabs
broken on one side or two adjacent tabs broken.
12. Install the drain cock, if removed.
13. Test the radiator for leaks.
Figure 33Tightening the Clinch Tabs
Figure 35Sealing the Tank to the Radiator Core
RADIATOR 6B2-21
OIL COOLER REPLACEMENT
1. Outlet tank.
2. Nuts from the oil cooler fittings.
3. Oil cooler and gaskets from the tank.
Clean
Clean and dry the gasket area.
Install or Connect
1. Gaskets to the oil cooler.
2. Oil cooler to the tank.
3. Nuts.
a
OIL COOLER GASKET REPLACEMENT
Remove the outlet tank to replace the oil cooler. The oil
cooler gaskets can be replaced without removing the
tank.

1. Radiator and lay it on a flat surface.
2. Bottom oil cooler nut and loosen the top nut.
3. Press the oil cooler into the hole and remove the
gasket using a small hook (figure 37).
4. Flow-dry all surfaces on the tank and oil cooler.
1. Gasket without lubrication.

Be sure it is seated properly inside the tip of
the fitting.
Reach into the oil cooler and push it into
position against the tank.
2. Oil cooler nuts.
Nuts to 20 N-m (15 ft. lbs.

Do not overtighten.
3. Leak test.
4. Radiator to the vehicle.
Figure 37Removing the Oil Cooler Gasket
Tighten

4. Outlet tank.
5. Test the radiator.
RECORE
If the radiator core is damaged beyond repair and the
other parts are serviceable, install the original inlet and
outlet tanks, oil cooler, radiator cap, and drain valve, along
with the new core and new gaskets.
6B-22 RADIATOR
SPECIFICATIONS
R/V
Fan Shroud to the
Radiator
4.3L
5.0L
5.7L
6.2L
7.4L
6 Nm
(53 in. lbs.)
6 Nm
(53 in. lbs.)
6 N-m
(53 in. lbs.)
6 N-m
(53 in. lbs.)
6 N-m
(53 in. lbs.)
Upper Fan Shroud to

the Lower Fan Shroud
6 N-m
(53 in. lbs.)
17 N-m
(13 ft. lbs.)
Upper Mounting Panel

17 N-m
(13 ft. lbs.)
Upper Mounting Brackets
17 N-m
(13 ft. lbs.)
Transmission Oil Cooler

Lines
Engine Oil Cooler Lines
17N m
(13 ft. lbs.)
27 N-m
(20 ft. lbs.)
24 N-m
(18 ft. lbs.)
24 N-m
(18 ft. lbs.)
24 N-m
(18 ft. lbs.)
G
4.3L
5.0L
5.7L
6.2L
7.4L
Fan Shroud to the

Radiator
27 N-m
(20 ft. lbs.)
3 N-m
(27 in. lbs.)
3 N-m
(27 in. lbs.)
5 N-m
(44 in. lbs.)
3 N-m
(27 in. lbs.)
Upper Fan Shroud to the

Lower Fan Shroud
6 N-m
(53 in. lbs.)
Transmission Oil
Cooler Lines
30 N-m
(22 ft. lbs.)
30 N-m
(22 ft. lbs.)
30 N-m
(22 ft. lbs.)
22 N-m
(16 ft. lbs.)
30 N-m
(22 ft. lbs.)
Engine Oil Cooler Lines
24 N-m
(18 ft. lbs.)
24 N-m
(18 ft. lbs.)
24 N-m
(18 ft. lbs.)
24 N-m
(18 ft. lbs.)
24 N m
(18 ft. lbs.)
6.2L
7.4L
Lower Mounting Panel
20 N-m
(15 ft. lbs.)
20 N-m
(15 ft. lbs.)
Lower Mounting Panel
17 N-m
(13 ft. lbs.)
17 N-m
(13 ft. lbs.)
Upper Mounting Brace
17 N-m
(13 ft. lbs.)
17 N-m
(13 ft. lbs.)
Fan Shroud to the Radiator
10 N-m
(89 in. lbs.)
10 N m
(89 in. lbs.)

(Heavy Duty Radiator)
17 N-m
(13 ft. lbs.)
17 N-m
(13 ft. lbs.)
Transmission Oil Cooler Lines
27 N-m
(20 ft. lbs.)
27 N-m
(20 ft. lbs.)
P(32)
RADIATOR 6B2-23
P(42)
4.8L
Lower M ounting Panel
17 N m
(13 ft. lbs.)
6 Nm
(53 in. lbs.)
5.7L
6 Nm
(53 in. lbs.)
6.2L
7.4L
17 N m
(13 ft. lbs.)
17 N m
(13 ft. lbs.)
6 Nm
(53 in. lbs.)
6 N-m
(53 in. lbs.)
17 N m
(13 ft. lbs.)
17 N m
(13 ft. lbs.)

(Heavy Duty Radiator)
27 N m
(20 ft. lbs.)
Transmission Oil Cooler Lines
27 N m
(20 ft. lbs.)
27 N m
(20 ft. lbs.)
27 N m
(20 ft. lbs.)
SPECIAL TOOLS
J-23699
J-24460-01
J-33419-A
1. O v e rflo w Tubge P re ssure A d a p te r

2. Q u ic k F ill A d a p te r C ap
3. R a d ia to r C ore R e m o v e r/In s ta lle r
F-02614
6B2-24 RADIATOR
6C-1
SECTION 6C
FUEL SYSTEM
CONTENTS
SUBJECT
PAGE
Description.....................................................................................................................................................................6C- 1
Air Cleaner.....................................................................................................................................................................6C- 2
Air Filter Element Replacem ent............................................................................................................................. 6C- 2
Carbureted Engine Fuel F ilte rs ..................................................................................................................................6C- 2
Fuel Filter Replacem ent..........................................................................................................................................6C- 2
Diagnosis Of WATER IN FUEL Light (Diesel Engine O nly)................................................................................ 6C- 3
Diesel Engine Fuel Filters............................................................................................................................................ 6C- 3
Draining The Fuel Filter............................................................................................................................................ 6C- 3
Diesel Fuel Filter Replacement................................................................................................................................6C- 4
Diesel Fuel Filter Assembly Component Replacem ent...................................................................................... 6C- 5
Fuel P u m p .....................................................................................................................................................................6C- 5
Fuel Pump Tests (Carbureted Engine)................................................................................................................... 6C- 5
Fuel Pump Tests (Diesel Engine)........................................................................................................................... 6C- 5
Fuel Pump Replacement..........................................................................................................................................6C- 6
Fuel T a n k.......................................................................................................................................................................6C- 7
Draining The Fuel Tank............................................................................................................................................ 6C- 7
Fuel System Cleaning (Carbureted Engine)........................................................................................................... 6C- 8
Diesel Fuel System C ontam ination....................................................................................................................... 6C- 8
Fuel System Cleaning (Diesel Engine)................................................................................................................... 6C- 9
Fuel Tank P urging.................................................................................................................................................... 6C- 9
Fuel Tank Leak T e s t................................................................................................................................................ 6C-10
Fuel Tank Replacement............................................................................................................................................6C-10
Fuel Tank Filler Neck................................................................................................................... ............................ 6C-10
Fuel L in es.................................................................................................................................................................. 6C-10
Fuel Gage Sending U n it.............................................................................................................................................. 6C-13
Fuel Gage Sending Unit Replacement................................................................................................................... 6C-13
Fuel Tank Selector V a lv e ............................................................................................................................................ 6C-13
Diagnosis Of Selector V alve....................................................................................................................................6C-13
Fuel Tank Selector Valve Replacement................................................................................................................. 6C-13
Accelerator C ontrols....................................................................................................................................................6C-16
Accelerator Control Cable........................................................................................................................................6C-16
Accelerator Pedal...................................................................................................................................................... 6C-16
S pe cifica tio n s.............................................................................................................................................................. 6C-17
Special T o o ls ................................................................................................................................................................ 6C-18
All new GM vehicles are certified by the United States Environmental Protection Agency as conforming to the require
ments of the regulations for the control of air pollution from new motor vehicles. This certification is contingent on certain
adjustments being set to factory standards. In most cases, these adjustment points either have been permanently sealed
and/or made inaccessible to prevent indiscrim inate or routine adjustm ent in the field. For this reason, the factory proce
dure for tem porarily removing plugs, cap, etc., for purposes of servicing the product, must be strictly followed and,
wherever practicable, returned to the original intent of the design. For vehicles sold in Canada and equipped with non
closed loop engines, also refer to the appropriate Canadian service manual supplement.
DESCRIPTION
This section covers information for carbureted and diesel engines only. For fuel system information on TBI equipped
vehicles, refer to the Fuel And Emissions Service M anual.
6C-2 FUEL SYSTEM
AIR CLEANER
CAUTION: The air cleaner also functions as a
flame arrestor in the event of engine backfire.
The air cleaner should be installed at all times
unless its removal is necessary for repair or
maintenance. To help reduce the risk of per
sonal injury and property damage, be sure that
no one is near the engine compartment before
starting the engine with the air cleaner re
moved. If engine backfire occurs with the air
cleaner removed, there could be a burst of
flame and possibly other fire in the engine com
partment.
On vehicles with diesel engines, do not use
starting fluidsimmediate engine damage can
result. Also take care not to let objects fall into
the engine if the air cleaner is removed. If the
engine is running, suction can pull loose ob
jects into the engine. Objects pulled or dropped
into the engine can cause costly engine dam
age.
When replacement of the air cleaner filter element is
necessary, an AC air filter element is recommended.
Refer to MAINTENANCE AND LUBRICATION (SEC.
OB) for change intervals. Operation of the vehicle in dusty
areas will necessitate more frequent replacement.
AIR FILTER ELEMENT

REPLACEMENT
NOTICE: Extreme care should be taken when
removing the filter element. Remove the filter
elem ent slowly to prevent dirt from falling into
the engine.
1.
2.
3.
4.
Wing nut.
Air cleaner cover from the base.
Air filter element.
All accum ulated dirt from the base.
i?
Inspect
Filter element for dam age or excessive dirt

accum ulation. Replace as necessary.
Seals or gaskets for damage.
Install or Connect
1. Air filter element.
2. Air cleaner cover.
3. Wing nut.
CARBURETED ENGINE FUEL FILTERS

The fuel filter element should be replaced at the inter
vals shown in MAINTENANCE AND LUBRICATION (SEC.
OB). Fuel filter elements are of the throw away type and
should be replaced, not cleaned.
Internal fuel filters are located in the inlet fitting of the
carburetor (Figure 1). The filter element (3) is placed in
the inlet hole with the gasket (2) surface outward. A spring
(4) pushes out against the element and compresses the
gasket (2) against the fuel inlet nut (1). A check valve is
also built into the filter element.
FUEL FILTER REPLACEMENT
++
1. Fuel line connection at the fuel inlet nut (1).

2. Fuel inlet nut (1).
3. Filter element (3), gasket (2), and spring (4).

1. Spring (4).
2. Filter element (3).
The inlet check valve must be installed in the
filter element to meet Motor Vehicle Safety
Standards (M.V.S.S.) for roll-over.
The new filter element must include the check
valve.
The check valve end of the filter element must
face toward the fuel line.
3. Fuel inlet nut (1).
1.
2.
3.
4.
Fuel In le t N ut
G a sket
F ilte r W ith C h e c k Valve
S p rin g
B-08098
Figure 1Carburetor Fuel Filter

Tighten
Fuel inlet nut to Specifications at the end of
this section.
4. Fuel line.
Start the engine and check for leaks.
FUEL SYSTEM 6C-3
DIAGNOSIS OF WATER IN FUEL LIGHT

(DIESEL ENGINE ONLY)
PROBLEM
CORRECTION
POSSIBLE CAUSE
Intermittent Light
Water in fuel filter.
Drain water from the fuel filter.
Light Stays On With

Engine Running
(Temperature Above
Freezing)
Fuel filter is clogged or contains water.
Drain the fuel filter. If no w ater is

drained and the light stays on, replace
the filter element.
Light Stays On With

Engine Running
(Temperature Below
Freezing)
Fuel filter is clogged with ice.
D rain the fuel filter. If no w ater is

drained, open the air bleed and check
for fuel pressure. Replace the filter ele
ment if there is no pressure.
Light Comes On At
High Speed Or During
Heavy Acceleration
Plugged fuel filter.
Replace the filter element.
Light Stays On
Continuously And
Engine Stalls And Will
Not Restart (After
Initial Start-Up).
Fuel filter or lines plugged.
Replace the filter element or check the

lines.
Light Stays On
Continuously And
Engine Stalls And Will
Not Restart (After
Refueling).
Large amounts of water pumped into the

tank.
Purge the fuel tank.
DIESEL ENGINE FUEL FILTERS

The diesel engine fuel filter is an inline type filter which
com bines several different functions. It acts as a filter,
water separator, water detector, water drain, and a fuel
heater (Figure 2).
The first stage of the filter element is a water coalesor.
The coalesor element combines small droplets of water
into larger drops. The water collects in the bottom of the
filter element for draining. The fuel then passes through
the second stage of the filter element which is a paper
filter.
The filter acts as a water detector by turning on the
WATER IN FUEL light on the instrum ent panel. The
probe of the water detector will touch water when 65 ml.
(2.2 fluid ounces) of water has collected in the filter. This
completes a circuit through the water to the cover assem
bly which turns on the WATER IN FUEL light.
NOTICE: If the WATER IN FUEL light comes

on and the fuel system is not purged of water,
fuel injection system damage may result.
When the light comes on, the filter should be drained

as soon as practical, but within one to two hours of engine
operation.
A water drain is located in the bottom of the fuel filter
assembly. By opening the water drain valve, water that
has collected in the bottom of the filter element can be
drained.
A fuel heater is located in the fuel filter assembly to
help prevent fuel waxing. The heater therm ostat turns the
heater on at about 0C (32F) and off at about 30C
(80F). The heater uses 7 to 13 amps depending on fuel
temperature.
DRAINING THE FUEL FILTER

1. Turn off the engine and apply the parking brake.
2. Remove the fuel filler cap to release any pressure or
vacuum in the fuel tank.
3. Place a suitable container under the filter drain
hose.
6C-4 FUEL SYSTEM
7.
8.
9.
10.
11.
12.
13.
14.
15.
W a te r Drain Valve
B a il W ire s
F uel F ilte r E le m e n t
A ir B leed
F ilte r A d a p te r
A ir B leed Port
R e s tric tio n S w itc h
F ue l H ea te r
W a te r S e n s o r
F-00796
Figure 2Diesel Fuel Filter

CAUTION: The water/diesel fuel mixture is
flammable, and could be hot. To help avoid
personal injury and/or property damage, do not
touch the fuel coming from the drain hose, and
do not expose the fuel to open flames or
sparks.
Be sure you do not overfill the container.
Heat (such as from the engine) can cause the
fuel to expand. If the container is too full, fuel
could be forced out of the container. This could
lead to a fire and the risk of personal injury
and/or vehicle damage.
4. Open the drain valve (7) two to three turns (figure 2).
5. Start the engine and allow it to idle for one to two
m inutes or until clear fuel is observed.
6. Stop the engine and close the drain valve (7).
7. Install the fuel filler cap.
8. Dispose of the drained m ixture in a proper manner.
DIESEL FUEL FILTER

REPLACEMENT
1 . Fuel filler cap to release any pressure or vacuum in
the fuel tank.

2. Both bail wires (8).
Drain fuel from the filter by opening the air bleed
(10) and the water drain valve (7).
Allow the fuel to drain into a suitable
container.
3.
Fuel filter element (9).
SI Clean
Any dirt from the fuel sealing surfaces of the filter
element and the filter adapter (11).
El
1.
2.
3.
New filter element.

Bail wires.
Close the drain valve (7).
A 3 mm (Vs-inch) inside diam eter hose to the air
bleed port (12).
4. The other end of the hose into a suitable container.
Disconnect the fuel injection pum p shut-off solenoid
wire.
NOTICE: If the engine is to be cran ked or
started with the air cleaner removed, take care
not to let objects fall into the engine. If the
eng in e is running, su ctio n can p u ll loose
o b jects into the engine. O bjects p u lle d or
d ro p p e d into the e n g in e can cause costly
engine damage.
Crank the engine for 10 to 15 seconds and then wait
one minute for the starter m otor to cool. Repeat until
clear fuel is observed com ing from the air bleed.
Close the air bleed.
5. Injection pump solenoid wire.
6. Fuel filler cap.
Start the engine and allow it to idle for five minutes.
Check the fuel filter for leaks.
FUEL SYSTEM 6C-5

DIESEL FUEL FILTER ASSEMBLY
COMPONENT REPLACEMENT
All component parts of the fuel filter assembly are
serviceable. These components include the filter adapter,
restriction switch, fuel heater, and the water sensor (figure
Always replace any damaged or worn O-rings, gaskets,

or seals. After replacing components, bleed air from the
filter to save cranking time. Start the engine and check for
leaks after replacing components.
2).
FUEL PUMP
All carbureted and diesel engines use a m echanical
fuel pump located on the front right side of the engine.
The pump is a diaphragm type pump and is actuated by a
rocker arm through a link and pull rod.
Some engines have a special fuel pump that has a me
tering outlet for a vapor return system. Any vapor that
form s is returned to the fuel tank along with hot fuel. This
reduces the chance of vapor lock because cool fuel from
the tank is always circulated through the fuel pump.
The fuel pump rocker arm is moved back and forth by a
rod which rides on an eccentric on the engine camshaft.
The rocker arm pulls down on the pump diaphragm
against spring pressure. This causes a vacuum in the
pump cham ber which draws fuel from the tank through
the inlet valve. The cam shaft rotates and releases pres
sure on the rocker arm. This allows the spring to act on
the diaphragm and force fuel out of the pump cham ber
through the outlet valve and into the fuel line to the carbu
retor or diesel fuel injection pump.
When the carburetor float rises and closes the needle
valve, fuel cannot leave the pum p chamber. The spring is
held compressed by the fuel pressure in the pump cham
ber. The rocker arm idles on the cam eccentric and only
moves enough to maintain pressure on the spring. A con
stant pressure is maintained on the fuel in the line to the
carburetor. This pressure is proportional to the force of the
spring.
W hen the immediate fuel needs of the diesel engine
are satisfied, pressure builds in the fuel line and pump
chamber. This pressure forces the diaphragm /piston to
make shorter and shorter strokes, until more fuel is
needed in the engine.
FUEL PUMP TESTS

(CARBURETED ENGINE)
If the fuel system is suspected of not delivering enough
fuel, it should be inspected as follows.
Inspect
Make certain that there is fuel in the tank.
For leaks at all fuel connections from the fuel tank to
the carburetor.
FUEL PUMP FLOW TEST

1. Remove the fuel supply line from the carburetor or fuel
injection pump and insert it into a suitable container.
2. Crank the engine.
3. The fuel pump should supply 237 ml (1/2-pint) or more
in 15 seconds.
4. If the flow is insufficient, check for a restriction.
5. If there are no restrictions, check fuel pump vacuum
and/or pressure.
FUEL PUMP PRESSURE TEST

1.
2.
3.
4.
Disconnect the fuel inlet line at the carburetor.

Install a low pressure gage to the line.
Start the engine.
Fuel pump pressure should be 27.5 to 44.8 kPa (4 to
6 V2 psi).
5. If the pressure is low, check for restrictions in the fuel
tank sender unit filter, lines, and hoses.
NOTICE: Hold the carburetor fuel inlet nut while
tig h te n in g the fu e l lin e fittin g to p re v e n t
carburetor damage.
6 . Connect the fuel inlet line to the carburetor.
FUEL PUMP VACUUM TEST

1. Disconnect the inlet hose at the fuel pump and connect
a vacuum gage.
2. Crank or run the engine until the maximum vacuum is
reached.
3. If the vacuum is less than 50.6 kPa (15-inches Hg),
replace the fuel pump.
4. If the vacuum is 50.6 kPa (15-inches Hg), check the fuel
line s and hoses fo r leaks, kinks, or s p lits by
disconnecting each section of line and connecting a
vacuum gage. Crank or run the engine until the
maximum vacuum is reached. The vacuum should be
at least 50.6 kPa (15-inches Hg).
FUEL PUMP TESTS

(DIESEL ENGINE)
If the fuel system is suspected of not delivering enough
fuel, it should be inspected as follows.
The engine should be running.
Inspect
Tighten any loose connections.
Make certain that there is fuel in the tank.

For leaks at all fuel connections from the fuel tank to
the injection pump.
The engine should be running.
Tighten any loose connections.
All hoses for flattening or kinks that would restrict the

flow of fuel.
Air leaks or restrictions on the suction side of the fuel
pump will seriously affect pump output.
6C-6 FUEL SYSTEM
25. Fuel P um p
26. B o lt
27. G a sket
F-00797
Figure 3Fuel PumpCarbureted 4.8L Engine

All hoses for flattening or kinks that would restrict the
flow of fuel.
Air leaks or restrictions on the suction side of the fuel
pump will seriously affect pump output.
FUEL PUMP FLOW TEST

1. Fuel line at the fuel filter inlet.
2. Fuel injection pump electric shut-off solenoid wire
(pink wire).
Place a suitable container at the end of the fuel filter
inlet line.
Crank the engine for 15 seconds.
The fuel pump should supply 237 ml (1/2-pint) or
more in 15 seconds.
FUEL PUMP PRESSURE TEST

1. Disconnect the fuel line at the inlet to the fuel filter
assembly.
2. Install a low pressure gage to the line.
3. Crank or run the engine for 10 to 15 seconds.
4. Fuel pressure should be 38 to 45 kPa (5.5 to 6.5 psi).
26. B o lt
27. G asket
31. Push Rod

F-00799
Figure 4Fuel PumpCarbureted 5.7L Engine

25.
26.
27.
28.
29.
30.
Fuel P um p
B o lt
G asket
B o lt
M o u n tin g Plate
G a sket
P ush Rod
FUEL PUMP VACUUM TEST

1. Disconnect the inlet line at the fuel pump.
Plug the hose or position it so fuel does not leak.
2. Connect a vacuum gage to the fuel pump inlet.
The engine will use fuel from the filter assembly.
4. Vacuum should be 41 kPa (12-inches Hg) or greater.
5. Replace the pump if vacuum is less than 41 kPa
(12-inches Hg).
FUEL PUMP REPLACEMENT

ALL ENGINES EXCEPT 7.4L
H

1.
2.
3.
4.
Fuel pipes and hoses from the fuel pump (25).

Bolts (26).
Fuel pump (25).
Gasket (27).
F-00800
Figure 5Fuel Pump6.2L Engine
FUEL SYSTEM 6C-7

f^l
Tighten
8. Fuel pipes and hoses to the fuel pump.
If it is difficult to start the outlet fitting, disconnect
the line at the carburetor or the diesel fuel
injection pump.
7.4L ENGINE
Fuel pipes and hoses from the fuel pump (35).
Bolts (36).
Fuel pump (35).
Gasket (37).
Plug (38).
6. The push rod (39).
5.
6.
7.
8.
Bolts (28).
Mounting plate (29).
Gasket (30).
The push rod (31) (if necessary).
-H - Install or Connect (Figures 3 through 5)
1. The push rod (39).

Apply some chassis grease to the rod and hold it
up against the camshaft.
Gasket sealer to the threads on the plug (38).
Plug (38).
Gasket (37).
Fuel pump (35).
Bolts (36).
1. The push rod (if removed).

Apply some chassis grease to the rod to hold it
up against the camshaft.
2. New gasket (30).
3. Mounting plate (29).
4. Bolts (28).
Tighten
Bolts alternately and evenly to 37 N m (27 ft.
lbs.).
Fuel pipes and hoses to the fuel pump.
If it is difficult to start the outlet fitting, disconnect
the line at the carburetor.
5. New gasket (27).
6. Fuel pump (25).
7. Bolts (26).
FUEL TANK
The fuel tank is located under the rear or the sides of
the vehicle. The fuel tank is held in place by two metal
straps that are attached to the underbody. Anti-squeak
strips are used between the tank and the straps to reduce
rattles and squeaks.
The fuel tank, filler cap, and fuel lines should be
checked for damage which could cause leakage. Replace
any dam aged or worn parts.
Before servicing the fuel tank or lines:
Disconnect the negative battery cable from the battery.
Place NO SMOKING signs near work areas.
Have a C 0 2 fire extinguisher nearby.
DRAINING THE FUEL TANK
++

There are two batteries in diesel engine vehicles.
Have a dry chemical (Class B) fire extinguisher in
the work area.
2. Fuel filler cap.
CAUTION: Never drain or store gasoline or

diesel fuel in an open container due to the
possibility of fire or explosion.
Wear safety glasses.

Siphon or pump fuel into an explosion proof container.
3. Fuel through the filler tube using a hand operated

pump.
6C-8 FUEL SYSTEM

If a hand operated pump cannot be used to
complete the draining, use a siphon at the main
(not return) fuel pipe at the fuel pump or the fuel
gage sending unit.
Install or Connect
1. Any lines or hoses.
2. Fuel filler cap.
3. New fuel gage sending unit gasket.

NOTICE: Take care not to fold or twist the
strainer when installing the sending unit as this
will restrict fuel flow.
4. Fuel gage sending unit using J-24187.
5. Fuel tank.
6. Fuel gage wire harness to the body harness.
FUEL SYSTEM CLEANING

(CARBURETED ENGINE)
7. All fuel lines.

8. A hose to the carburetor inlet line.
Disconnect the inlet line from the carburetor.
CAUTION: This procedure will not remove all

fuel vapor. Do not attempt any repair on the
tank or fille r neck where heat or flame is
required, as an explosion resulting in personal
injury could occur.
9. The other end of the hose into a four liter (one gallon)
fuel can.
10. Battery cable.
11. Six gallons of clean gasoline into the fuel tank.
Crank the engine until the fuel can is about one-half
full. This will purge the fuel pump.
Contaminated fuel or other foreign material in the tank

can usually be removed by cleaning; however, if the fuel
tank is rusted internally, it should be replaced.
Do not overheat the starter.
I Remove or Disconnect
12. Carburetor inlet line to the carburetor.
Tool Required:
J-24187 Fuel Gage Sending Unit Tool
Negative battery cable.
Engine harness connector at the distributor.
Have a dry chem ical (Class B) fire extinguisher near
the work area.
Fuel from the fuel tank.
Refer to Draining the Fuel Tank.
Fuel tank.
Refer to Fuel Tank Removal.
Fuel filter. Replace the filter if it is plugged.
Fuel gage sending unit using J-24187.
Locate th e ta n k aw ay from heat, flam e, or oth er
sou rces o f ig n itio n .
If the strainer is contaminated or clogged, a new

strainer should be installed upon reassembly.
Remaining fuel from the tank by rocking the tank.
Flush the fuel tank with hot running water for at least
five minutes.
Water from the fuel tank by rocking the tank.
Make sure that the water is completely removed.
Fuel feed pipe at the fuel pump.
Clean
Fuel lines by applying air pressure in the opposite
direction of fuel flow in the line.
Install or Connect
Tool Required:
Lines and pipes.
Tighten
Fittings to 30 N-m (22 ft. lbs.).
2. New strainer on the fuel gage sending unit (if
necessary).
Use low air pressure to clean the pipes of the
fuel gage sending unit.
Check all connections for leaks and tighten all hose

clamps.
13. Engine harness connector to the distributor.
DIESEL FUEL SYSTEM

CONTAMINATION
Fungi and other m icro-organism s can survive and
m ultiply in diesel fuel if water is present. The fungi can be
present in any part of the fuel handling system. These
fungi grow into long strings and will form into large
globules. The growths appear slim y and are usually black,
green, or brown. The fungi may grow anywhere in the fuel
but are most plentiful where diesel fuel and water meet.
As the fuel is agitated (when service station tanks are
being filled), fungi are distributed throughout the tank and
may be pumped into a vehicle.
Fungi use the fuel as their main energy supply and
need only trace amounts of water and minerals. As they
grow and multiply, they change fuel into water, sludge,
acids, and products of metabolism. The most common
symptom is fuel filter plugging; however, various metal
components (fuel tank, lines, and injection pump) can
corrode.
CAUTION: To avoid personal injury, do not

come into physical contact with biocides.
If fungi have caused fuel system problems, use a diesel
fuel biocide to sterilize the fuel system. Do not exceed the
dosage recommended on the label. Discontinue the use
of a biocide when towing a trailer. It is permissible to have
biocide in the fuel when starting to tow, but do not add any
biocide while towing.
Steam cleaning may be necessary if most of the fungus
growth cannot be removed with biocides.
FUEL SYSTEM 6C-9

FUEL SYSTEM CLEANING
(DIESEL ENGINE)
CAUTION: Never drain or store diesel fuel in an
open container due to the possibility of fire or
explosion.
Crank the engine for 15 seconds with one minute

cooling periods until clean fuel appears from each
nozzle.
11. HPCA lead to the injection pump.
&
WATER IN THE FUEL SYSTEM

Battery cables.
Fuel from the tank.
Refer to Draining the Fuel Tank.

Fuel tank.
Fuel gage sending unit,
f c y l Clean
5.
6.
7.
8.
Fuel tank.
The tank should be replaced if it is rusted
internally.
The pick-up filter or replace if necessary.
The check valve assembly.
Main fuel hose at the fuel pump.
Fuel return line at the injection pump.
Use low air pressure to blow out the lines toward the
rear of the vehicle.
Replace the pipes if they are rusted internally.
Fuel injection pump shut-off solenoid wire.
Fuel filter.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Fuel gage sending unit.

Fuel tank.
Fuel lines to the tank.
Clean diesel fuel into the tank until it is 1/4 full.
Fuel tank cap.
Fuel hoses to the fuel pump.
Battery cables.
cooling periods until clean fuel is pumped out.
Use a suitable container to catch the fuel.
New fu e l filte r. R efer to D ie se l Fuel F ilte r
Replacement.
A hose from the return line at the fuel injection pump to
a closed metal container with a capacity of at least 8L
(2-gallons).
If the engine temperature is above 52C (125F),
activate the HPCA (Housing Pressure Cold Advance)
on the in je c tio n pum p. T h is can be done by
disconnecting the two lead connectors at the Engine
Temperature Switch and bridging the connector with a
jumper wire.
cooling periods until clean fuel appears at the return
line.
Two lead connectors to the Engine Temperature
Switch.
Remove the jumper wire.
Disconnect the lead to the HPCA solenoid (on the
injection pump).
Crack open each injection line at the nozzle. Use two
wrenches to prevent nozzle damage.
12.
13.
Tighten
Injection line to nozzle fitting to 25 N m (20 ft.

lbs.).
Use two w renches to prevent nozzle
damage.
Fuel injection pump shut-off solenoid wire.
Start the engine and allow it to idle for 15 minutes.
Make sure the fuel return line is in the metal
container and that the container does not
overflow.
Remove the hose from the metal container.
Fuel return line to the injection pump.
Check for leaks.
GASOLINE IN THE FUEL SYSTEM

Engine Will Run Or Start
1. Drain the fuel tank.
2. Fill the tank with diesel fuel.
3. Run the engine for 15 minutes.
Engine Will Not Run

1. Drain the fuel tank.
2. Fill the tank with diesel fuel.
3. Remove the fuel injection pump shut-off solenoid
wire.
4. Remove the fuel line between the fuel filter and the
injection pump.
5. Connect a hose to the fuel filter outlet and run it to a
closed metal container.
6. Crank the engine for 15 seconds with one minute
cooling periods to purge gasoline from the system.
7. Install the fuel line between the fuel filter and the
injection pump.
8. If the engine temperature is above 52C (125F),
a c tiv a te th e H P C A (H o u s in g P re s s u re C o ld
Advance) on the injection pump. This can be done
by disconnecting the two lead connectors at the
E n gin e T e m p eratu re S w itch and b rid g in g the
connector with a jum per wire.
9. Install the fuel injection pump shut-off solenoid wire.
10. Start the engine and remove the jum per wire.
11. Connect the two lead connector.
12. Run the engine for 15 minutes.
FUEL TANK PURGING

The fuel tank should be purged before being repaired.
++
1. Fuel tank from the vehicle.

2. Fuel gage sending unit.
3. All remaining fuel from the tank.
Inspect
Fuel tank for any rem aining fuel.
6C-10 FUEL SYSTEM

1. Tap water into the tank until it is full.
Move the tank to the flushing area (wash rack).
Agitate the water vigorously and then drain it.
2. Gasoline emulsifying agent into the tank.
Use an available emulsifying agent such as
Product-Sol No. 913 or equivalent.
3. Water to the fuel tank.
Refer to the emulsifying agent specifications for
the mixture ratio.
Agitate the mixture for ten minutes.
Drain the tank completely.
Fill the tank with water until it overflows.
Completely flush out any remaining mixture.
Drain the fuel tank.
Use an explosion meter (if available) to check for a
negative reading.
Perform the required service work.
FUEL TANK LEAK TEST

If fuel is leaking from the tank, the tank should be
replaced. Make sure that the fuel lines are not leaking
onto the tank.
1. Remove the fuel tank.
2. Drain the tank.
3. Plug all of the outlets.
4. Apply 7 to 10 kPa (1 to 11/2 psi) air pressure through the
vent tube.
5. Test for leaks with a soap solution or by submersion.
6. Replace the tank if a leak is found.
FUEL TANK REPLACEMENT

CAUTION: To help avoid personal injury when a
vehicle is on a hoist, provide additional support
for the vehicle at the opposite end from which
com ponents are being removed. This w ill
reduce the possibility of the vehicle falling off
the hoist.
E 3 Remove or Disconnect (Figures 7 through 9)
1. Fuel from the tank.
2. Fuel tank retaining straps.
Support the fuel tank.
3. Sending unit wire, hoses, and ground straps.
Lower the tank.
4. Fuel tank from the vehicle.

1. Fuel tank into the vehicle.
Support the tank.
2. Sending unit wire, hoses, and ground straps.
3. Fuel tank retaining straps with the anti-squeak pieces.
Cement the anti-squeak material securely to the
tank with 25 mm (1-inch) wide coverage for 10 cm
(4-inches) on each end.
Tighten
Retaining strap bolts or nuts to specifications.
FUEL TANK FILLER NECK

A restrictor and deflector is built into the fuel filler neck
on gasoline engine vehicles to help prevent refueling with
leaded gasoline. The opening in the restrictor will only
adm it the sm aller unleaded gas nozzle spout. The nozzle
must be fully inserted to bypass the deflector (figures 10
through 12).
FUEL FILLER CAP

The fuel tank filler neck is equipped with a screw type
cap. The cap requires several turns counterclockwise to
remove. The long threaded area allows fuel tank pressure
to escape while the cap is being removed. A torque
limiting device prevents overtightening. To install, turn the
cap clockwise until a clicking noise is heard.
N O T IC E : If a fu e l f ille r c a p re q u ire s
replacement, use only a cap with the same
features. Failure to use the correct cap can
result in a serious malfunction of the system.
FUEL LINES
NOTICE: Fuel and vapor hoses and pipes are
specially manufactured. It is important to use
re p la c e m e n t h o s e o r p ip e m e e tin g GM
Specifications. Hoses and pipes not m eeting
GM Specification could cause early failure or
failure to m eet emission standards.
When replacing fuel feed and return pipes, always use
welded steel tubing meeting GM Specification 124 M or its
equivalent. The replacement pipe must have the same
type fittings as the original pipes to ensure integrity of the
connection.
Never replace fuel pipe with copper or aluminum
tubing.
Check and replace any damaged O-rings or washers.
Fuel pipes should be inspected occasionally for leaks,
dents, or kinks.
Follow the same routing as the original pipe.
Pipes must be properly secured to the frame to prevent
chafing. A minimum clearance of 6 mm (1/4-inch) must
be maintained to prevent contact and chafing.
FUEL AND VAPOR HOSES

NOTICE: Fuel and vapor hoses are specially
m a n u fa c tu r e d . It is im p o r ta n t to use
replacem ent hoses that m eet GM Specification
6163-M. These hoses are identified by the word
Fluoroelastomer marked on them. Hoses not
so marked could cause early failure or failure to
m eet emission standards.
Do not use rubber hose within 10 cm (4-inches) of any
part of the exhaust system or within 25 cm (10-inches) of
the catalytic converter.
FUEL SYSTEM 6C-11
Figure 7Fuei Tank MountingR/V Pickup
A. T ig h te n Thi
N u t F irs t
B. H o o k M u s t
Face F orw ard
B
F-00803
Figure 8Fuel Tank Mounting Utility Vehicle

and Suburban
Figure 9Fuel Tank Mounting G Van
6C-12 FUEL SYSTEM
Figure 10R/V Filler Neck
F-00806
Figure 12G-Van Filler Neck
FUEL SYSTEM 6C-13
FUEL GAGE SENDING UNIT

50. L o ckin g Cam
51. Fuel Gage
S e n d in g U nit
52. G a sket
53. In-Tank Fuel
F ilte r
53
Diesel engine vehicles have a check valve that will

permit fuel to pass if the tank filter becomes plugged with
paraffin during cold weather operation.
When this plugging occurs, the last four gallons of fuel
will not be used due to the location of the check valve.
Therefore it is important to keep the fuel tank above the
1/4 mark at temperatures below -6C (-20F) when using
number two diesel fuel.
FUEL GAGE SENDING UNIT

REPLACEMENT
B-08104

Figure 13Fuel Gage Sending Unit
The fuel gage sending unit is mounted in the top of the
fuel tank. It is held in place by a cam lock ring. A gasket is
used between the tank and the sending unit.
Sending units have either two or three nipples to attach
hoses. These hoses are the fuel feed, fuel return, and
vapor hoses.
On some sending units a wire is attached to the unit;
while on other sending units, connectors attach directly to
the sender.
IN TANK FUEL FILTER

A woven plastic filter is located on the lower end of the
fuel pickup tu b e jn the fuel tank (figure 13). This filter
prevents dirt and water from entering into the fuel line
unless it becomes completely submerged in water. The
filt e r is s e lf c le a n in g a nd n o rm a lly re q u ire s no
maintenance. Fuel stoppage at this point indicates that
the fuel tank contains an abnormal amount of sediment or
water and should be thoroughly cleaned.
Tool Required:
Fuel from the tank.
Fuel tank from the vehicle.
Locking cam (50) using J-24187.
Fuel gage sending unit (51).
Gasket (52).

Tool Required:
New gasket.
Fuel gage sending unit.
Take care not to fold or twist the strainer or fuel
flow will be restricted.
Locking cam using J-24187.
Fuel tank into the vehicle.
FUEL TANK SELECTOR VALVE

The fuel tank selector valve is operated by a switch on
the instru m e nt panel. The sw itch controls fuel tank
switching and fuel gage indication in a single operation.
A simple check can be made to determine if the fuel
tank selector valve is working by listening for selector
valve motor operation when the switch is pressed.
DIAGNOSIS OF SELECTOR VALVE

CHECKING THE INSTRUMENT PANEL
SIDE OF THE HARNESS
R efer to fig u re s 14 th ro u g h 16 to d ia g n o s e the
instrum ent panel side of the selector valve harness.
CHECKING THE SELECTOR VALVE SIDE

OF THE HARNESS
1. Make sure there is about 40 liters (10 gallons) of fuel in
one tank and about 20 liters (5 gallons) in the other
tank.
2. Remove the harness connector from the fuel tank
selector valve.
3. Install a known good selector valve.

4. Activate the fuel tank selector switch and note the gage
readings of the right and left tanks.
5. The system is operating properly if a change is
indicated between the tanks. Therefore, the original
selector valve was the problem.
6. If a change is not indicated, there is an open in the
harness between the connector on the cowl and the
selector valve.
7. Refer to INSTRUMENT PANEL (SEC. 8C) if the fuel
gage does not register accurately.
FUEL TANK SELECTOR VALVE

REPLACEMENT
2. Hose shield (60) and brace (61).
3. Electrical connector from the selector valve (62).
60-14 FUEL SYSTEM
DISCONNECT SELECTOR VALVE HARNESS AT THE CONNECTOR

ON THE COWL.
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST LIGHT TO

THE FEMALE HARNESS CONNECTOR AND PROBE THE REMAINING
TERMINAL.
TEST LIGHT SHOULD LIGHT IN BOTH SWITCH POSITIONS.

T
1
TEST LIGHT LIGHTS.
TEST LIGHT DOES NOT LIGHT.

CHECK FOR PROPER GROUND CONNECTION (BLACK OR
BLACK WITH PINK WIRE) AT THE BUSS BAR.
----
-------
---------------------
CHECK FOR A PROPER CONNECTION TO THE IGNITION

RECEPTACLE IN THE FUSE PANEL.
I
CHECK FOR PROPER CONNECTION AT THE SELECTOR
VALVE SWITCH. CHECK FOR BENT TERMINAL ON THE
BACK OF THE SWITCH AND IN THE SWITCH
CONNECTOR. CHECK FOR VOLTAGE AT THE PINK WIRE
AND FOR GROUND AT THE BLACK WIRE.
] -----------------------------------------------------------------------------
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST LIGHT

TO GROUND AND PROBE THE LIGHT GREEN WIRE OF THE
FEMALE CONNECTOR ON THE COWL. THE TEST LIGHT
SHOULD LIGHT IN ONE SWITCH POSITION ONLY.
s
TEST LIGHT LIGHTS.
TEST LIGHT DOES NOT LIGHT.
..... . _______ 1 i
REPLACE THE SELECTOR VALVE SWITCH.
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST
LIGHT TO THE FEMALE HARNESS CONNECTOR AND
PROBE THE REMAINING TERMINAL.
TEST LIGHT SHOULD LIGHT IN BOTH SWITCH POSITIONS.
IF THE TEST LIGHT DOES NOT LIGHT, THERE IS AN

OPEN IN THE HARNESS BETWEEN THE SWITCH AND
THE CONNECTOR.
I
IF A PROBLEM STILL EXISTS, PERFORM A CHECK ON
THE SELECTOR VALVE SIDE OF THE HARNESS.
F-00807
Figure 14Diagnosis of the Instrument Panel Side of the Selector Valve Harness
FUEL SYSTEM 6C-15
> 917253
-.8 P N K - 3 0 - * - - T T 0 ]
BULKHEAD
CONNECTOR
691723?
30
30
[ T o } - - * - . 5 PN K-3 0-
'
IN ST
C LU STE R
IN ST
CONN
(SEE
(BASE)
'
150
\
OH
CLUSTER (B A S E )
ALSO GAGES)
1202001* SM
LEFT ---- ^
.8
LT GRN
5 3 ( HOT
.8 OK GR
5 4 (HOT
(A U X ILIA R Y)
RIGH T TANK
D
PM
/ALVE
CO CO
>
---- T
z z
O
oLoc
o
FUEL TANK
S E LE C T O R VALVE
& METER SWITCH
-...
tICMT ,
tIGM T-*
LE F T
ro
ui in
mm
>
.8
FU EL TANK
S E LE C T O R SWITCH
PNK/BLK-830(SXL )
M l 1220
(O) H t t t t C
Juliet >4
i m u sj
.8
.8 BLK
I 5 0 ( HDT)
IGN FUSED
20 AMP
z z
a OC
CD CD
P N K / W H T - 9 3 0 (H D T )
o
ro
I
(PRODUCTION)
L E F T TANK
F USE
BUS BAR GRO
BLOCK
B-08116
Figure 15Auxiliary Fuel Tank Wiring

4. Fuel and vapor hoses.
Note the position of the hoses for installation.
5. Screws (63).
6. Valve (62).

1.
2.
3.
4.
5.
6.
To F uel Tank S e le c to r Valve

54.
55.
56.
57.
58.
A n d S e n d in g U nit
F use Panel
S e le c to r Valve S w itc h
In s tru m e n t Panel S ide O f H a rn e ss
C o n n e c to r
S e le c to r Valve S ide O f H a rn e ss
F-08117
Figure 16Auxiliary Fuel Tank Instrument

Panel Wiring
Valve (62).
Screws (63).
Fuel and vapor hoses in the correct position.
Electrical connector.
Brace (61) and hose shield (60).
6C-16 FUEL SYSTEM
62
00
LU
Fuel R eturn
R ig h t Feed (Orange)
L e ft Feed (Yellow)
R ig h t R eturn (Pink)
L e ft R eturn (Blue)
S h ie ld
Brace
S e le c to r Valve
B o lt
B-08119
Figure 17Selector Valve
ACCELERATOR CONTROLS
The accelerator pedal controls the throttle through a ca
ble. There are no linkage adjustments. The throttle cable
must be replaced with an identical replacement part.
70
All linkages and cables must be checked to assure free

movement with no rubbing, chafing, or binding. The throt
tle must operate freely w ithout binding between full closed
and wide open throttle.
ACCELERATOR CONTROL CABLE

Observe the following when performing service on the
accelerator control cable.
The retainer must be installed with the tangs secured
over the head of the stud (figure 18).
The conduit fitting at both ends of the cable must have
the locking tangs expanded and locked into the
attaching holes.
The braided portion of the cable must not come into
c o n ta c t w ith the fro n t of dash s e a le r d u rin g
replacement.
Flexible components (hoses, wires, conduit, etc.) must
not be routed within 50 mm (2-inches) of the moving
parts of the accelerator linkage unless routing is
positively controlled.
Lube all pivot points w ith A cce lerator Linkage
Lubricant (1052541 or equivalent).
71. W a sh er
B-08121
Figure 18Control Cable Attachment
ACCELERATOR PEDAL
Observe the following when performing service on the
accelerator pedal.
The m ounting surface between the support and the
dash panel must be free of insulation. The carpet
ana paaaing in the pedal and tunnel area must
FUEL SYSTEM 6C-17

positioned to lay flat and be free of wrinkles and
bunches.
Slip the accelerator control cable through the slot in
the rod before installing the retainer in the rod. Make
sure it is seated properly. Use care in pressing the
retainer into the hole so the cable is not kinked or
dam aged (figure 19).
The linkage must operate freely without binding
between closed throttle and full throttle.
Wire, hoses, cable, and other flexible components
must not be placed within 13 mm (0.52-inch) of the
cable or rod at any point in their travel.
75.
76.
77.
78.
R e ta in e r (M u st B ear A g a in s t Pedal Rib)

S p rin g
Rod
B-08122
Figure 19Accelerator Pedal Assembly
SPECIFICATIONS
FUEL PUMP BOLT TORQUE
4.8L
5.7L
5.7L
6.2L
6.2L
7.4L
E n g in e .............................................................................................................. 23 N-m (17

Engines (Top B o lts ) ...................................................................................... 37 N-m (27
Engines (Bottom Bolts)...................................................................................... 4 N-m (3
Engine (Top B o lts ) ........................................................................................ 33 N-m (24
Engine (Bottom B o lts ) ...................................................................................... 8 N-m (6
E n g in e ............................................................................................................ (37 N-m (27
ft.
ft.
ft.
ft.
ft.
ft.
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
R/V Model With Base Tank N u ts ............................................................................. 6 N-m (4 ft.

R/V Model With RPO NL2 B o lts .........................................................................33 N-m (24 ft.
Utility Vehicle And Suburban N u t s .................................................................... 16 N-m (12 ft.
G-Van With Base Tank B o lts..................................................................................5 N-m (45 in.
G-Van With RPO NL7 Bolts..................................................................................11 N-m (95 in.
G-Van N u ts .............................................................................................................. 13 N m (10 ft.
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
FUEL TANK MOUNTING STRAP FASTENERS
FUEL INLET NUT TORQUE

1-Barrel 1 M E F ...............................................................................................45 N-m (33 Ft. Lbs.)
4-Barrel M 4 M E ...............................................................................................62 N-m (46 Ft. Lbs.)
6C-18 FUEL SYSTEM
SPECIAL TOOLS
6C1-1
SECTION 6C1
CARBURETORS
CONTENTS
SUBJECT
PAGE
Carburetor Model 1M EF...........................................................................................................................................6C1- 2

Description................................................. ............................................................................................................ 6C1- 2
Diagnosis of 1MEF Rochester Carburetor............................................................................................................... 6C1- 7
On-Vehicle Service (1MEF)........................................................................................................................................6C1-15
Electric C h o k e ........................................................................................................................................................ 6C1-15
Idle Solenoid............................................................................................................................................................ 6C1-16
Carburetor Replacement........................................................................................................................................6C1-17
Carburetor A djustm ents........................................................................................................................................6C1-17
Carburetor Models M4ME and M4MEF..................................................................................................................... 6C1-21
Description.............................................................................................................................................................. 6C1-21
Carburetor Identification........................................................................................................................................6C1-21
Diagnosis of M4ME and M4MEF Rochester Carburetors.......................................................................................6C1-28
On-Vehicle Service (M4ME and M4MEF)................................................................................................................. 6C1-37
Float Level - External C h e c k .................... ...........................................................................................................6C1-37
Choke Checking P ro ce d u re ..................................................................................................................................6C1-37
Checking idle Stop Solenoid (ISS)....................................................................................................................... 6C1-37
Checking Throttle Kicker........................................................................................................................................ 6C1 -38
Fuel Filter R eplacem ent........................................................................................................................................ 6C1-38
Carburetor Mounting T o rq u e ................................................................................................................................6C1-38
Carburetor Replacement........................................................................................................................................6C1 -38
Idle Mixture Adjustment (Heavy-Duty Emission Vehicles O n ly )...................................................................... 6C1-39
Idle Speed A d ju stm e n t.......................................................................................................................................... 6C1 -40
Throttle Kicker Adjustment....................................................................................................................................6C1 -40
Float A djustm ent.................................................................................................................................................... 6C1 -40
Pump A d ju s tm e n t.................................................................................................................................................. 6C1-41
Air Valve Return Spring A d ju stm e n t................................................................................................................... 6C1-41
Choke Stat Lever Adjustment................................................................................................................................6C1-42
Choke Link and Fast Idle Cam Adjustm ent......................................................................................................... 6C1 -42
Primary Side Vacuum Break Adjustment............................................................................................................. 6C1-42
Secondary Side Vacuum Break A djustm ent.......................................................................................................6C1-44
Air Valve Link A d ju s tm e n t....................................................................................................................................6C1-45
Unloader Adjustm ent..............................................................................................................................................6C1-45
Secondary Throttle Lockout Adjustment............................................................................................................. 6C1-46
S pe cifica tio ns............................................................................................................................................................ 6C1-47
Special T o o ls .............................................................................................................................................................. 6C1-48
All new GM vehicles are certified by the United States Environmental Protection Agency as conform ing to the require
ments of the regulations for the control of air pollution from new motor vehicles. This certification is contingent on certain
adjustments being set to factory standards. In most cases, these adjustment points either have been permanently sealed
and/or made in accessible to prevent indiscrim inate or routine adjustment in the field. For this reason the factory proce
dure for temporarily removing plugs, cap, etc., for purpsoes of servicing the product, must be strictly followed and,
wherever practicable, returned to the original intent of the design. For vehicles sold in Canada and equipped with non
closed loop engines, also refer to the appropriate Canadian service manual supplement.
6C1-2 CARBURETORS
CARBURETOR MODEL 1MEF
Figure 11 MEF Carburetor
DESCRIPTION
Model 1MEF carburetors are single bore downdraft
carburetors using a triple venturi along with a discharge
tube nozzle (figure 1 ).
A power valve piston assem bly and m etering rod
control the fuel flow in the main metering and power
systems of the carburetor. The tapered metering rod is
M odel N um ber
Day O f Year
S o u rc e C o d e
Year
A s s e m b ly P la n t C o d e
S h ift Id e n tific a tio n
B-06647
Figure 2Carburetor Identification
attached to the power piston and moves in a fixed

metering jet to provide the fuel flow for varying engine
demands. On 1MEF carburetors, a factory set metering
rod adjusting screw controls the position of the metering
rod in the jet. This screw is located in the air horn and
should not be turned as this could result in engine
damage or increased exhaust emissions.
Model 1MEF incorporates an integral automatic choke
system which uses an electrically heated choke coil. The
vacuum diaphragm unit is mounted externally on the air
horn and connects to the therm ostatic coil lever through a
connecting link.
The electric choke coil is contained in a choke housing,
which is mounted on a bracket attached to the float bowl.
Special rivets are installed to retain the factory setting of
the choke coil and provide a non-adjustable design.
An integral, pleated-paper fuel inlet filter is mounted in
the fuel bowl behind the fuel inlet nut to give maximum
filtration of incoming fuel. A check valve is used in the
filter inlet to prevent fuel draining from the fuel system
after rollover.
To improve hot engine starting and meet evaporative
emission requirements, fuel vapors from the carburetor
bowl are vented to a vapor canister on some models. A
tube (location F) is added to the air horn to connect the air
horn and canister.
Other features of the carburetors include an aluminum
throttle body for decreased weight and improved heat
distribution. A thick throttle body to bowl insulator gasket
keeps excessive engine heat from the float bowl.
All 1 MEF models have seals added in the float bowl to
seal the power piston drive rod and the pum p lever. This
prevents fuel vapors from escaping to atmosphere. During
unit repair, the seals and retainer, where used, must be
removed prior to immersion of the float bowl in carburetor
cleaner.
The carburetor model identification is stamped on a
vertical portion of the foat bowl, adjacent to the fuel inlet
nut (figure 2 ).
If replacing the float bowl, follow the m anufacturers
instructions contained in the service package so that the
identification number can be transferred to the new float
bowl.
An electrically operated idle stop solenoid and dual
throttle return springs are used on all carburetors.
The throttle lever has a spun-in plastic bushing which is
used as a bearing surface. The bushing will withstand
normal cleaning time in an approved cold immersion type
carburetor cleaner. The bushing is not serviced separately
and should not be removed from the carburetor throttle
lever.
Six basic systems of operation are used (figures 3
through 8 ).
Float
Power
Idle
Pump
Main Metering
Choke
CARBURETORS 6C1-3
226
215
215.
218.
226.
228.
231.
234.
F uel In le t F ilte r
F uel F ilte r S p rin g
F loa t
F loa t H in g e Pin
F loa t N eedle
F loa t N ee dle Seat
A. In te rn a l V e n t
B. V e n t Tube to C a n is te r
C. C h e c k Valve Seat
D. F uel In
E. C h e c k Valve
F. Valve C lo s in g S p rin g
F-01479
Figure 3Float System
240.
247.
248.
252.
256.
258.
260.
310.
317.
A.
B.
C.
D.
Rod - P um p
C up - P um p P lu n g e r
S p rin g - P u m p P lu n g e r
S p rin g - P u m p R eturn
G u id e - P um p D isch a rg e S p rin g
S p rin g - P um p D isch a rg e Ball
Ball - P u m p D isch a rg e
Lever - P um p and P ow er Rod
L in k - P um p
Pum p P lu n g e r Head
Pum p D u ra tio n S p rin g
P um p D isch a rg e C ha nn el
P um p Jet
248
B-06645
Figure 4Pump System
6C1-4 CARBURETORS
2:66.
274.
276.
279.
282.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
Rod - P ow er P isto n
P ow er Valve P isto n A s s e m b ly
S p rin g - P ow er P isto n
M e te rin g Rod and S p rin g A s s e m b ly
Je t - M ain M e te rin g
T h ro ttle Valve
V acuum C h a n n e l
M ain V e n tu ri
B o o s t V e n tu ri
M ain D isc h a rg e N ozzle
L ow er Id le A ir Bleed
M ain W ell
Fuel Feed O rific e
Part T h ro ttle A d ju s tin g S crew
Top M ain W e ll A ir Bleed
M ain W ell to A s p ira to r Bleed
A p
F-01481
Figure 5Main Metering System - 1 MEF
266.
274.
276.
279.
282.
310.
314.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Rod - P ow er P isto n
Pow er Valve P isto n A s s e m b ly
S p rin g - P ow er P isto n
M e te rin g Rod and S p rin g A s s e m b ly
Je t - M ain M e te rin g
Lever - P u m p and Pow er Rod
L in k - P ow er Rod
T h ro ttle Valve
M ain D isch a rg e N ozzle
L ow er id le A ir B leed
M ain W ell
M e te rin g Rod A d ju s tin g S crew
S e tscre w
M e te rin g Rod A d ju s tin g S crew Plug
Top M ain W ell A ir Bleed
M ain W ell to A s p ira to r Bleed
266
276
B-06644
Figure 6Power System - 1 MEF
CARBURETORS 6C1-5
10.
15.
20.
40.
43.
F a st Idle Cam
F a st Idle Cam L in k
C ho ke S h aft, Lever and L in k A s s e m b ly
C h o ke S h a ft and Lever A s s e m b ly
C ho ke S tat Lever
B ow l S id e V a cuu m Break A s s e m b ly
V a cuu m Break Lever and L in k A s s e m b ly
C ho ke Valve
T h e rm o s ta tic C oil
P lu n g e r B u c k in g S p rin g
(not used on all m o d e ls )
F-01482
Figure 7Choke System
6C1-6 CARBURETORS
282.
286.
326.
333.
A.
B.
C.
D.
E.
F.
G.
J e t-M a in M e te rin g
Id le Tube A s s e m b ly
N e e d le -Id le M ix tu re
P lu g -Id le M ix tu re N ee dle
T h ro ttle Valve
Id le C ha nn el R e s tric tio n
Top Idle A ir Bleed
L ow er Idle A ir B leed
O ff-Id le Port
Idle D isch a rg e O rific e
T im e d V a cuu m Port
B-06642
Figure 8Idle System - 1 MEF
CARBURETORS 6C1-7
DIAGNOSIS OF 1MEF ROCHESTER CARBURETOR

The following diagnostic procedures are for carburetor related problems and their effects on vehicle performance. Other
v e h icle syste m s can also cause problems and should be checked when listed on the chart.
PROBLEM
Engine Cranks
Normally - Will Not
Start or Starts Hard
POSSIBLE CAUSE
1. Im proper starting procedure used.
2. Ignition system malfunction.

3. Choke not operating properly.
4. Engine loaded with fuel. (Improper start

ing procedure used or choke unloader
misadjusted.)
5. No fuel in carburetor.
6 . Engine flooded. To check for flooding, re
move the air cleaner and look into the

carburetor venturi for fuel dripping from
nozzle.
Engine Starts - Will

Not Keep Running
1. Improper starting procedure used.
2 . Choke not operating properly.
3. Engine does not have correct fast idle

speed when cold.
4. Vacuum break assembly malfunctioning

or misadjusted.
CORRECTION
1. Check with the customer to determine
if proper starting procedure, outlined in
the O w ners and Drivers M anual , is
used.
2. Check ignition system. Refer to EN
GINE ELECTRICAL (SEC. 6 D).
3. Check for free movement, and com
plete opening and closing, of choke
valve. See Choke Checking Proce
dure and Checking Electric Choke
later in this section.
4. Check with the custom er to determine
the O w ners and Drivers M anual , is
used.
Adjust choke unloader.
5. Inspect fuel filter(s) for being plugged.
Check fuel pump pressure and vol
ume. Replace pump if necessary. In
s p e c t fu e l lin e s fo r le a k s a nd
restrictions.
Check the float level, and adjust if
necessary.
6 . Remove the air horn.
C heck float for restricted movement
or being loaded.
Inspect float needle and seat for
wear and dirt or chips.
If foreign material is found in the car
buretor, clean the fuel system and car
b u re to r. R e p la c e fu e l filte r ( s ) as
necessary.
Check float level, and adjust if neces
sary.
1. Check with the custom er to determ ine
the O w ners and Drivers M anual, is
used.
2. Check for free movement and complete
opening and closing of choke valve.
See Choke Checking Procedure and
Checking Electric Choke later in this
section.
3. Check for free movement of fast idle
cam and linkage. See Choke Check
ing Procedure later in this section. Ad
ju s t fast idle speed. See Em ission
Control Information Label.
4. See Vacuum Break Checking Proce
dure later in this section. Adjust vac
uum break assembly to specification.
6C1-8 CARBURETORS
DIAGNOSIS OF 1MEF ROCHESTER

CARBURETOR (CONT.)
PROBLEM
Not Keep Running
(Cont.)
POSSIBLE CAUSE
5. Idle speed too low.
6 . Air leaks at carburetor flange/insulator
gasket(s), or at intake manifold gasket.

Vacuum hoses disconnected or installed
improperly.
7. Not enough fuel in carburetor.
8 . Carburetor flooding.
Engine Idles
Abnormally (Too Fast
or Too Slow)
1. Idle speed misadjusted.
2. Idle stop solenoid m alfunctioning. Faulty

solenoid circuit wiring.
3. Choke not operating properly or fast idle
cam sticking or binding.
4. Throttle linkage or throttle shaft sticking

or binding.
CORRECTION
5. Adjust idle speed. See Emission Con
trol Information Label.
6 . Use a pressure oil can to spray light oil
or kerosene around carburetor throttle
body (do not spray at throttle shaft
ends), and manifold to head m ounting
surfaces.
If engine RPM changes, torque car
buretor to manifold bolts and/or intake
manifold bolts to specification. If neces
sary, replace the carburetor flange/in
sulator gasket(s) and/or intake manifold
gasket. Check condition and routing of
vacuum hoses. Correct or replace as
necessary.
7. Inspect fued filter(s) for being partially
plugged. Replace as necessary.
ume. Replace pum p if necessary. In
restrictions.
C heck the float level, and adjust if
necessary.
Check float for restricted movement
or being loaded.
Inspect flo at needle and seat for
wear and dirt or chips.
necessary.
sary.
1. Adjust idle speeds. See Emission Con
2. See Idle Stop Solenoid Checking Pro
cedure later in this section.
3., Check choke valve and fast idle cam
for free movement. Check for complete
section.
4. Check throttle linkage and throttle shaft
for smooth and free operation. Clean
with suitable solvent. Replace throttle
body if necesasry.
CARBURETORS 6C1-9
DIAGNOSIS OF 1MEF ROCHESTER

CARBURETOR (CONT.)
PROBLEM
Engine Idles
Or Tool Slow) (Cont.)
POSSIBLE CAUSE
CORRECTION
5. Air leaks at carburetor flange/insulator

improperly.
5. Use a pressure oil can to spray light oil

or kerosene around carbuertor throttle
ends), and manifold to head mounting
surfaces.
necessary.
6. Check PCV system. Clean or replace
PCV valve and hoses as necessary.
7. Adjust timing. See Emission Control In
formation Label.
8. Check operation. Refer to the Fuel
and Emissions Service Manual.
9. Clean carburetor if necesasry. Adjust
idle mixture per specified procedure.
10. Replace if necessary.
11. Remove the air horn.
or being loaded.
wear, and for dirt or chips.
b ureto r. R e p la ce fu e l filte r(s ) as
necessary.
6 . PCV system malfunctioning.
7. Ignition timing misadjusted.

8. Distributor vacuum or mechanical ad
vance malfunctioning.
9. Idle system restricted or incorrect idle
mixture adjustment.
10. Restricted air cleaner element.
11. Carburetor flooding.
Check float level, and adjust if necessary.
Engine Diesels (After

Run) Upon Shut Off
1. Minimum idle speed misadjusted.
1. Adjust minimum idle speed. See Emis
2. Idle stop solenoid malfunctioning. Faulty

solenoid circuit wiring.
3. Choke not operating proeprly or fast idle
2 . See Idle Stop Solenoid Checking Pro
sion Control Information Label.
4. Throttle linkage or throttle shaft sticking

or binding.

improperly.
cedure later in this section.

3. Check choke valve and fast idle cam
opening and closing of check valve.
section.
4. Check throttle linkage and throttle shaft
for smooth and free operation. Clean
with suitable solvent. Replace throttle
body if necessary.
surfaces.
sulator gasket(s) and/or intake manofld
necessary.
6C1-10 CARBURETORS
DIAGNOSIS OF 1M E F RO CH ESTER
CA RBU RETO R (CONT.)
PROBLEM
Engine diesels (After
Run) Upon Shut Off
(Cont.)
Engine Hesitates On
Acceleration
* Hesitates During
Cold Engine
Operation.
POSSIBLE CAUSE
6 . PCV system m alfunctioning.
7. Ignition tim ing retarded (causes throttle

valve to be opened farther than normal
to obtain correct idle speed).
8 . Lean idle mixture (causes throttle valve
to be opened farther than normal to ob
tain correct idle speed).
CORRECTION
6 . Check PCV system. Clean or replace

form ation Label.
8 . Clean carburetor if necessary. Adjust
idle mixture per specified procedure.
1. M alfunctioning pump system.

Make a quick check of the pump sys
tem: With the engine off, look into the
carburetor bore and observe pump dis
charge jet; actuate throttle lever. A full
stream of fuel should emit from the jet.
1 . Remove air horn and check pum p cup.
2 . * Choke not operating properly.
2.
3. * Vacuum break assembly m alfunction

ing or misadjusted.
3.
4. * Thermae system m alfunctioning.
4.
5. * Early Fuel Evaporation (EFE) system

malfunction.
6 . Ignition tim ing misadjusted.
5.
7. Distributor vacuum or m echanical ad

vance m alfunctioning.
8 . Float level too low.
7.
6.
8.
9. Power piston sticking. Missing or dam

aged power piston spring, power piston
rod, power rod link, or pump and power
rod lever.
9.
10. Metering rod hanger bent or metering

rod misadjusted.
10.
If cracked or hardened, replace the

pump plunger cup and spring.
Inspect pump well for scoring. Re
place float bowl if necessary.
Check for restricted pump passages.
Clean and blow out passages w ith
compressed air.
Check the pump discharge ball for
proper seating.
Check for complete opening and clos
ing of choke valve. See Choke Check
ing Procedure and Checking Electric
Choke later in this section.
See Vacuum Break Checking Proce
uum break to specification.
Check operation. Refer to the Fuel
and Emissions Service M anual.
Adjust timing. See Emission Control In
formation Label.
C heck operation. Refer to ENGINE
ELECTRICAL (SEC. 6 D).
sary.
Check power piston operation: push
piston down against piston rod and re
lease; it should move freely in bore and
return to its up position. Rotate throttle
to wide open; piston should move up
ward in bore.
If piston does not move freely, clean
power piston and bore.
If piston does not return when de
pressed, or does not move upward
when th ro ttle is opened, check for
missing or dam aged parts. Replace as
necessary.
Inspect metering rod hanger for dam
age. Replace power piston assembly if
necessary. Adjust metering rod to spec
ification.
CARBURETORS 6C1-11
PROBLEM
Engine Hesitates On
Acceleration (Cont.)
POSSIBLE CAUSE
11. Restricted main metering jet or adjust
able part throttle fuel feed orifice.
Engine Has Less Than 1. Ignition system malfunction.

Normal Power At
2. Ignition tim ing misadjusted.
Normal Acceleration
4. Plugged air cleaner element.
5. Exhaust system restricted.
6 . Thermae system m alfunction.
7. Early Fuel Evaporation (EFE) system

m alfunction.
8 . Transmission malfunction.
10. Fuel filter(s) partially plugged.

11. Faulty fuel pump, or leaking or restricted
fuel lines.
12. Float level too low.
rod lever.

rod misadjusted.
able part throttle fuel feed orifice. Loose
main metering jet.
CORRECTION
11. If foreign material is found in the carbu
retor, clean the fuel system and carbu
reto r. R e p la c e fu e l filte r ( s ) as
necessary.
2. Adjust tim ing. See Emission Control In
form ation Label.
3. C heck operation. Refer to ENGINE
4. Replace element.
5. Check for restrictions. Correct as nec
essary.
6 . Check operation. Refer to the Fuel
and Em issions Service M anual.
8 . Refer to transmission diagnosis.
9. Check for complete opening and clos
10. Inspect fuel filter(s). Replace as neces
sary.
11. Check fuel pump pressure and volume.
Replace pump if necessary. Inspect
fuel lines for leaks and restrictions.
12. Check the float level, and adjust if nec
essary.
13. Check power piston operation: push
ward in bore.
missing or damaged parts. Replace as
necessary.
14. Inspect metering rod hanger for dam
age. Replace power piston assem bly if
necessary. Adjust metering rod.
necessary. If m etering je t is loose,
tighten.
6C1-12 CARBURETORS
CARBU RETO R (CONT.)
PROBLEM
Less Than Normal
Power On Heavy
Acceleration Or At
High Speed
POSSIBLE CAUSE
CORRECTION
1. Carburetor throttle valve not going wide

open.
1. Correct throttle linkage to obtain wide

4. Distributor mechanical advance malfunc
tioning.
6 . Exhaust system restricted.
7. Thermae system malfunction.
8 . Early fuel Evaporation (EFE) system mal
function.
9. Transmission malfunction.
10. Choke no* operating properly.

12. Faulty fuel pump or leaking or restricted
fuel lines.
rod lever.

rod misadjusted.
able part throttle fuel feed orifice. Loose
main metering jet.
Engine Surges

tioning.
improperly.
open throttle in carburetor.

formation Label.
4. Check operation. Refer to ENGINE
5. Replace element.
6 . Check for restrictions. Correct as nec
essary.
9. Refer to transmission diagnosis.
sary.
essary.
ward in bore.
pressed or does not move upward
when throttle is opened, check for
necessary.
retor. R e p la c e fu e l filte r(s ) as
necessary. If metering jet is loose,
tighten.
surfaces.
CARBURETORS 6C1-13
PROBLEM
POSSIBLE CAUSE
Engine Surges (Cont.)
4. PCV system m alfunctioning.

6 . Thermae system malfunction.

malfunction.
8 . Contaminated fuel.
fuel lines.
12. Float needle sticking in seat.

rod lever.

rod misadjusted.
able part throttle fuel feed orifice.
CORRECTION
3. Continued
necessary.
essary.
and Em issions Service M anual.
8 . Check for water or excessive alcohol in
fuel.
sary.
essary.
12. Replace float needle and seat.
ward in bore.
pressed or does not move upw ard
necessary.
necessary.
6C1-14 CARBURETORS
CARBU RETO R (Cont.)
PROBLEM
Poor Gas Mileage
* Black Smoke From
Tail Pipe
POSSIBLE CAUSE
1. Customer driving habits.
2. Wrong speedometer gear.
3. Low tire pressure or incorrect tire size.

4. Transmission malfunction or in wrong
gear.
5. Fuel leaks.
6 . * Plugged air cleaner element.
7. * Choke not operating properly.
8 . * Vacuum break assembly malfunction
ing or misadjusted.
improperly.
13. Engine in need of service.

15. * High fuel level in carburetor or flood
ing.

rod lever.
CORRECTION
1. Run mileage test, with customer driving
if possible, make sure vehicle has
2000-3000 miles (3 200-4 800 km) for
the break-in period.
2 . Check odom eter against m easured
mile. Replace speedometer gear if nec
essary.
3. Inflate tires to specifications and use
correct tire sizes.
5. Inspect fuel tank, fuel lines and fuel
pump for any fuel leakage.
6 . Replace element.
8 . See Vacuum Break Checking Proce
formation Label.
surfaces.
buretor manifold bolts and/or intake
necessary.
13. Check engine compression.
essary.
15. Inspect float for restricted movement or
being loaded.
Check float needle and seat for wear
and dirt or chips.
If foreign material is found in carbure
tor, clean fuel system and carburetor.
Replace fuel filter(s) as necessary.
Check float level; and adjust if neces
sary.
ward in bore.
CARBURETORS 6C1-15
CA RBU RETO R (Cont.)
PROBLEM
CORRECTION
POSSIBLE CAUSE
Poor Gas Mileage

(Cont.)

rod misadjusted.
18. * Metering rod worn or damaged.
19. * Main metering jet worn or loose.
Gasoline Odor
1 . Fuel feed or vapor return line leaking.

2. Leak in fuel tank.
3. Disconnected or leaking fuel tank vent

lines or hoses to canister(s).
4. Purge lines not connected, .improperly
routed, plugged or pinched.
5. Carbon canister(s) loaded.
6 . Faulty fill cap.
Fuel Starvation
1. Fuel filter(s) plugged.

2. Fuel lines leaking, restricted, or misrouted.
3. Faulty fuel pump.
16. Continued
when th ro ttle is opened, ch eck for
necessary.
18. Inspect metering rod. Replace if neces
sary.
19. Inspect metering jet. Replace if neces
sary. If loose, tighten.
1. Repair/replace as required.
2. Purge tank and repair or replace tank
as required.
3. Connect, repair/replace lines as re
quired.
4. Connect, clean, or reroute lines as re
quired.
5. Compare weight of canister with a new
one. Replace if necessary.
6 . Install new cap.
sary.
2. Repair/replace, clean, or reroute as re
quired.
Replace pump if necessary.
ON-VEHICLE SE R V IC E (1M E F )
ELECTRIC CHOKE
Inspect
Remove the air cleaner. With the engine off, hold
the throttle half open. Open and close the choke
several times. Watch linkage to be certain all links
are connected and there are no signs of damage.
If the choke or linkage binds, sticks, or works
sluggishly, clean it with Choke Cleaner X-20-A or
equivalent. Use cleaner as directed on the can.
Refer to the disassem bly instructions for additional
direction if cleaning does not correct the problem.
Do not lubricate the linkage.
Visually inspect the carburetor to be certain all
vacuum hoses are connected. Inspect hoses for
cracks, abrasions, h ardn ess or o the r sign s of
deterioration. Replace or correct as necessary.
The vacuum break diaphragm shaft should be fully

extended when the engine is off. If the shaft is not
fully extended, replace the vacuum break assembly.
Start engine the vacuum break diaphragm shaft
should fully retract within 10 seconds. If the unit fails
to retract, replace the vacuum break assembly.
Allow the choke to cool so that when the throttle is
opened slightly, the choke blade fully closes. This
c h e c k m u s t be p e rfo rm e d a t an a m b ie n t
temperature of about 21 C (70F).
Start the engine and determine the tim e required for
the choke blade to reach its full open position.
(Start tim ing when the engine starts.) If the choke
plate fails to open fully within five minutes, proceed
with the rem aining steps.
Check voltage at the choke heater connection with
the engine running. If the voltage is approxim ately
12-15 volts, replace the electric choke unit. If the
v o lta g e is low o r zero, c h e c k a ll w ire s and
6C1-16 CARBURETORS
Figure 10Installing the Choke Coil Rivets

connections. If the connections at the oil pressure
switch are dirty or corroded, the oil warning lamp
will be off with the ignition switch On and the
engine off. If the fuse is blown, the radio or turn
signal indicator will be inoperative. Repair wires or
replace fuses as necessary.
IDLE SOLENOID
L*
Inspect
Turn on the engine control switch, but do not start
the engine.
If all wiring and fuses are good, replace the oil

pressure switch.
Open the throttle to allow the solenoid plunger to

extend.
Hold the throttle lever wide open, feel the end of the
plunger and disconnect the wire at the solenoid.
1. Air cleaner.
Plunger should move. Some spring tension should

be felt.
2 . The choke electrical connector.
3. Rivet heads and retainers.
If the plunger did not move, back out Ve hex screw

(counter clockwise) one full turn and repeat step 3
and 4.
Align a #21 drill (0.156-inch) on the rivet head

and drill only enough to remove the rivet head
(figure 9).
If the plunger moves in step 5, connect the wire to

the solenoid and adjust the idle speed.
Use a drift and a small hammer to drive the

re m a in d e r of th e riv e ts from th e ch oke
housing.
If the plunger did not move in step 5, insert test light

(1893 bulb or smaller) between the solenoid feed
wire and ground.
Use care in drilling to prevent damage to the

choke cover or housing.
4. The choke cover assem bly from the housing.
5. The choke coil from the housing.
1 . The choke cover and coil assembly in the choke
housing.
Align the notch in the cover with the raised
c a s tin g p ro je c tio n on th e h ou sin g co ver
flange.
Make sure the coil pick-up tang engages the
inside choke coil lever.
2. Retainers and rivets using a suitable blind rivet
installing tool (figure 10 ).
3. Electrical connector.
Start the engine and check the operation of the
choke.
4. Air cleaner.
If the light lights, replace the solenoid.
If the light does not light, locate the cause of the

open circuit in the solenoid feed wire.
Air cleaner.
Electrical connector from the solenoid.
Solenoid from the float bowl assembly.
+ 4- Install or Connect
1 . Solenoid.
Hold the choke valve wide open so the fast

idle cam follower clears the fast idle cam.
Turn the solenoid until it contacts the lever
tang.
3. Air cleaner.
Check and adjust the idle speed.
CARBURETORS 6C1-17
Clean
450
All traces of the old gasket from the carburetor

flange and intake manifold.

1. Heat shield and insulator gaskets to the intake
manifold.
CAUTION: Extinguish all open flames while

filling and testing carburetor with gasoline to
avoid personal injury.
2. Carburetor.
It is good shop practice to fill the carburetor
float bowl before installing the carburetor. This
reduces the strain on the starting motor and
b a tte ry a n d re d u c e s th e p o s s ib ility o f
backfiring while attempting to start the engine.
Operate the throttle several tim es and check
the discharge from pump jets before installing
the carburetor.
3. Carburetor attaching nuts.
&
Tighten
Both nuts to 4.1 N-m (36 in. lbs.) and then both
nuts to 22 N-m (16 ft. lbs.).
4. Accelerator linkage.
5. E le c tric a l c o n n e c to rs fo r the choke and
solenoid.
idle
6 . Fuel and vacuum
450.
451.
452.
453.
N ut
In s u la to r G a ske t
H eat S h ie ld
Intake M a n ifo ld
lines. Refer to the Em ission

Control Label, if necessary, for vacuum line routing
information.
7. Air cleaner.
Adjust
B-09229
Figure 11Carburetor installation
CARBURETOR ADJUSTMENTS
CARBURETOR REPLACEMENT
F lo o d in g , s tu m b le on a c c e le r a tio n a n d o th e r
performance complaints are, in many instances, caused
by the presence of dirt, water or other foreign matter in
the carburetor. To aid in dia gn osin g the cause, the
carburetor should be removed carefully from the engine
w ithout draining fuel from the bowl. Contents of the fuel
bowl may then be examined for foreign materials as the
carburetor is disassembled.

1. Air cleaner assembly.
2. Fuel and vacuum lines from the carburetor.
Make note of the vacuum hose routing.
3. E le c tric a l c o n n e cto rs fo r th e choke and
solenoid.
5. Carburetor attaching nuts.
6 . Carburetor.
7. Insulator gaskets and heat shield.
Idle speed, as outlined later.
idle
A c a rb u re to r is d e s ig n e d to m eet th e p a rtic u la r
requirements of the engine, transmission and vehicle and
although they may look alike, they are not usually
interchangeable. Refer to carburetor part number and/or
specifications when making adjustments.
Before suspecting the carburetor as the cause of poor
engine perform ance or rough idle; check the ignition
system including distributor, tim ing, spark plugs and
w ires. C heck the a ir cleaner, e vaporative e m ission
system, EFE System, PCV system, EGR valve and engine
compression. Also inspect intake manifold, vacuum hoses
and c o n n e c tio n s fo r le a k s and c h e c k to rq u e s of
carburetor mounting bolts/nuts.
Make all a d ju stm e n ts w ith the eng in e at norm al
operating tem perature, choke full open, and the air
cleaner installed. Except as noted, air conditioning should
be o ff and all vacuum lines and all electrical leads
connected. Refer to Specifications at the end of this
section for carburetor adjustm ent specifications. Gages
and tools for m aking adjustments are included in the
Universal Gage J-9789D.
6C1-18 CARBURETORS
A.
H e x W re n c h
B-09230
Figure 13^-Base Idle Adjustment

7. Start the engine and bring it to a normal operating
te m p e ra tu re , ch o ke va lve o p e n , and th e a ir
conditioning off.
8 . Connect an ACCURATE tachom eter to the engine.
9. Check the ignition tim ing, and adjust if necessary,

by following the procedure described on the Vehicle
Emission Control Information label.
Figure 12Removing the idle Mixture Needle Plug

IDLE MIXTURE ADJUSTMENT
In the case of a m ajor carburetor overhaul, throttle body
re p la c e m e n t, or hig h id le CO as in d ica te d by an
emissions inspection, the idle mixture may be adjusted.
Adjusting the mixture by other than the following method
may violate Federal and/or state laws.
Tool Required:
J-29030-B Idle Mixture Needle Socket
1. Set parking brake and block drive wheels.
2. Remove the carburetor from the engine.
3. Drain the fuel from the carburetor into a container.
4. Remove the idle m ixture needle plug (figure 12).
Invert carburetor, and support it to avoid
dam aging external components.
Make two parallel hacksaw cuts in the throttle
body, between the locator points near the idle
mixture needle plug. The distance between
the cuts depends on the size of the punch to
be used.
Cut down to the plug, but not more than
1 / 8 -inch beyond the locator point.
Place a flat punch at a point near the ends of
the saw marks. Hold the punch at a 4 5 angle,
and drive it into the throttle body to break the
casting away, to expose the plug.
Use a center punch to break the plug apart, to
uncover idle m ixture needle.
Remove all loose pieces of plug.
5. Reinstall the carburetor on the engine.
6 . P la ce th e tra n s m is s io n in PARK (a u to m a tic
transmission) or NEUTRAL (manual transmission).
10. Use J-29030-B to turn the mixture needle (1/8 turn

at time), in or out, to obtain the highest RPM (Best
Idle).
11. Adjust the idle speed solenoid to obtain the curb
idle speed on the Emission Control Information
label.
12. Again try to readjust the mixture needle to obtain
the highest idle RPM. The adjustm ent is correct
when the highest RPM (Best Idle) is reached with
the m inimum number of mixture needle turns from
the seated position.
13. If necessary, readjust the idle speed solenoid to
obtain the specified curb idle speed.
14. Check and if necessary, adjust the base idle speed
solenoid (solenoid deactivated) and the fast idle
speed to the specification shown on the Emission
Control Information label.
15. Turn off the engine, and remove the block from the
drive wheels.
IDLE SPEED ADJUSTMENT (Figure 13)

1 . Engine must be warm with the choke wide open.
2. The fast idle cam follower must be off the steps of

the cam.
See the Emission Control Information label.
3. Set the curb idle to specification. Turn the solenoid
in or out to adjust RPM.
The solenoid should be energized.
4. Turn a 1/s Hex screw to adjust the low idle speed to
450 RPM.
The solenoid should not be energized.
CARBURETORS 6C1-19
CHOKE UNLOADER ADJUSTMENT (Figure 17)

1. If the choke coil is warm, cool it down to the point
where the choke valve will close fully.
2. Hold the throttle valve wide open.
3. Gage between the lower edge of the choke valve
and the inside of the air horn.
4. Bend the tang to adjust.
FAST IDLE ADJUSTMENT (Figure 14)

1. Prepare the vehicle for adjustments according to the
Ignition tim ing must be set per label
2. A d just the curb idle speed w ith the idle stop
solenoid.
3. Place the cam follower tang on the high step of the
cam.
4. Support the lever with pliers and bend the tang in or
out to obtain the specified fast idle RPM.
CHOKE COIL LEVER ADJUSTMENT (Figure 15)

1. Place the fast idle cam follower on the highest step
of the fast idle cam.
2. Hold the choke valve com pletely closed.
3. Bend the link to adjust.
A 3 mm (0.120-inch) plug gage must pass
through the hole in the lever and enter the
hole in the casting.
CHOKE ROD (FAST IDLE CAM) ADJUSTMENT

(Figure 16)
1. W ith the fast idle adjustment made, the fast idle
cam follower must be held firm ly on the second step
of the fast idle cam and against the highest step.
2. Hold down on the choke valve so the rod is in the
end of the slot.
3. Gage between the lower edge of the choke valve (at
the center) and the inside air horn wall.
Refer to Specifications.
4. Bend the rod at point A to adjust.
6C1-20 CARBURETORS
3. Push down on the choke valve (com press the

plunger bucking spring and seat the plunger stem
on models so equipped).
4. Gage between the lower edge of the choke valve
and the inside of the air horn wall.
Hold the gage vertical.
5. Bend the link at point A to adjust.
FLOAT ADJUSTMENT (Figure 19)

VACUUM BREAK ADJUSTMENT (Figure 18)
1. Place the fast idle cam follower on the highest step
of the cam.
2. Use an outside vacuum source to seat the vacuum
break diaphragm.
On delay feature models, cover the plug and
the purge bleed hole with a 1 inch square of
m a s k in g ta p e . R e m o ve th e ta p e a fte r
adjustment.
Figure 18Vacuum Break Adjustment
Tool Required:
J-34817 Float Positioning Tool Kit
1 . Remove the air horn and gasket.
2. Attach J-34817-2 to the float bowl using an air horn

attaching screw.
3. Place J-34817-3 in the base with the contact pin
resting on the edge of the float lever.
4. Measure the distance from the top of the casting to
the top of the index at the toe of the float.
Use J-9789-90.
Figure 20Metering Rod Adjustment
CARBURETORS 6C1-21
5. If more than 2 /3 2 from specificatio n, use
J-34817-30 to bend the lever up or down. Remove
J-34817-30 and m easure, repeating until w ithin
specification.
6 . Check float alignment.
7. Install the air horn and gasket.
METERING ROD ADJUSTMENT (Figure 20)

1 . Remove the metering rod.
Hold the throttle valve wide open.

Push down on the metering rod against spring
tension.
Slide the metering rod out of the slot in the
holder.
2. Back out the idle stop solenoid.

Hold the throttle valve completely closed.
3. Hold the power piston down and swing the metering
rod holder over the flat surface of the bowl casting
next to the carburetor bore.
The gasket must be removed.
4. Gage between the end of the metering rod holder
and the top of the casting.
Use the specified plug gage.
Gage should have a slide fit.
5. Bend at point A to adjust.
CARBURETOR MODELS M4ME AND M4MEF

the service package, and stamp or engrave the num ber
on the new float bowl.
METERING SYSTEMS
B-09586
A single float cham ber supplies fuel to all carburetor

bores. A float, float needle with pull clip, and a float
needle seat, are used to control the level of fuel in the
float chamber. A vacuum -operated power piston and
metering rods control the air/fuel metering in the prim ary
bores of the carburetor. Tapered m etering rods are
attached to the power valve piston assembly, and move in
fixed metering jets, to provide the fuel flow for varying
engine demands. A factory-set adjustable part throttle
screw, used on all models, precisely positions the tapered
portion of the metering rods in the jets. (On M4MEF
m odels, the factory-set rich stop adjusting bushing
precisely positions the enrichm ent portion of the metering
rods in the jets.)
Figure 21Carburetor Identification
DESCRIPTION
Models M4ME and M4MEF are four barrel, two stage
carburetors with three major assemblies: the air horn,
flo a t bowl, and th ro ttle body. T hey have six basic
operating systems (figures 21 through 31).
Float
Power
Idle
Pump
Main Metering
Choke
The first M indicates this carburetor is of a Modified
prim ary metering open loop design.
The 4M is the model designation, indicating it is a
four barrel carburetor. The remaining letters designate
specific features.
E Has an electric choke.
F has an adjustable wide open throttle mixture
control.
CARBURETOR IDENTIFICATION (Figure 21)

The ca rb uretor id e n tific a tio n n um ber is stam ped
vertically on the float bowl near the secondary throttle
lever. Refer to this num ber before servicing the carburetor.
If replacing the float bowl assembly, follow instructions in
Air valves and tapered metering rods control the air/fuel

mixture in the secondary bores during increased engine
air flow at wide open throttle. On M4MEF models, the
factory-set secondary well air bleed adjusting screw
provides additional control of the air/fuel mixture during
wide open throttle.
PUMP SYSTEMS
The pump system on all models uses a throttle actuated
pump plunger, operating in the pump well. The pump
provides extra fuel during quick throttle openings.
CHOKE SYSTEMS
A electrically heated choke coil provides the choke
valve closing force for cold startup and for correct opening
tim ing during warmup. A vacuum break assembly(s)
controls initial choke valve opening at startup to provide
sufficient air flow to the engine. An unloader tang on the
throttle lever forces the choke valve open to purge a
flooded engine when the accelerator is pressed to the
floor. The fast idle cam, following choke valve movement,
acts as a graduated throttle stop to provide increased idle
speed during warmup.
6C1-22 CARBURETORS
A.
B.
C.
D.
236.
237.
238.
239.
240.
375.
377.
In te rn a l B o w l V e n ts
F lo a t C h a m b e r
In le t C h e c k Valve
V e n t Tube to C a n is te r
F lo a t H in g e Pin
F lo a t
F lo a t N e e d le P u ll C lip
F lo a t N e e d le
F lo a t N e e d le Seat
Fuel In le t F ilte r
Fuel F ilte r S p rin g
F-01883
Figure 22Float System

IDLE STOP SOLENOID (ISS)
Federal (Non-California) V8 Engines
With Manual Transmission.
The e le c tric Idle S top S o le n o id (ISS), on th ese
applications, provides the desired engine idle speed, and
prevents dieseling when the ignition is switched off.
THROTTLE KICKER ASSEMBLY

California V8 Engines
A vacuum operated Throttle Kicker assembly, found on
th e s e a p p lic a tio n s , re ta rd s th ro ttle clo sin g d u rin g
deceleration, to improve emission control. Vacuum to the
kicker is controller by the Throttle Return Control system,
w hich is fu rth e r d e s c rib e d in D R IV E A B ILIT Y AND
EMISSIONS - CARBURETED (SEC. 6 E8 ).
CARBURETORS 6C1-23
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
F ixed Idle A ir By-Pass

L ow er Idle A ir B leed
T im e d V acuum P orts
O ff-Id le O p e ra tio n
P rim a ry T h ro ttle Valve
Iflle D ischa rg e O rific e
O ff-Id le Port
Id le Tube
Id le C hannel R e s tric tio n
Idle A ir Bleed
P rim ary M e te rin g Je t

Idle M ix tu re N ee dle
Idle M ix tu re N ee dle Plug
F-01884
Figure 23Idle System - M4ME
A.
B.
C.
D.
E.
F.
G.
H.
J.
Id le Tube
Id le A ir B leed
Idle C h a n n e l R e s tric tio n
L ow er Id le A ir B leed
O ff - Id le Port
Idle D isc h a rg e O rific e
F ixe d Id le A ir By-Pass
T im e d V a cuu m Ports
420
248. P rim a ry M e te rin g J e t
420. Idle M ix tu re N e e d le
422. Idle M ix tu re N e e d le Plug
F-01885
Figure 24Idle System - M4MEF
6C1-24 CARBURETORS
A.
B.
C.
D.
E.
F.
G.
H.
212.
213.
218.
248.
Part T h ro ttle A d ju s tin g S crew (Do N ot Turn o r Rem ove)

M ain W ell A ir B le ed s
M ain D isch a rg e N ozzle
B o o st V e n tu ri
M ain V e n tu ri
M ain W ell
Pow er Valve P isto n A s s e m b ly
P rim a ry M e te rin g Rod
Pow er P isto n S p rin g
P rim a ry M e te rin g Je t
F-01886
Figure 25Main Metering System - M4ME
Part T h ro ttle A d ju s tin g S crew

(Do N o t Turn o r Remove)
R ich S to p A d ju s tin g B u sh in g
(Do N o t Turn o r Rem ove)
R ich S to p A d ju s t Plug
V a cuu m C h a n n e l
M ain W ell
M ain W e ll A ir B le ed s
M ain D is c h a rg e N ozzle
B o o s t V e n tu ri
M ain V e n tu ri
213. P rim a ry M e te rin g Rod

218. P ow er P is to n S p rin g
248. P rim a ry M e te rin g Je t
Figure 26Main Metering System - M4MEF
F-02719
CARBURETORS 6C1-25
A.
B.
C.
D.
E.
F.
A ir Valve
E c c e n tric C am
B a ffle
S e co n d a ry T h ro ttle Valve
S e co n d a ry D ischa rg e N ozzle
M e te rin g D isc
32.
50.
212.
213.
218.
248.
S e c o n d a ry M e te rin g Rod
A ir H orn B a ffle
P ow er Valve P isto n A s s e m b ly
P rim a ry M e te rin g Rod
P ow er P isto n S p rin g
P rim a ry M e te rin g Je t
F-01888
Figure 27Power System - M4ME
A.
B.
C.
D.
E.
41.
67.
68.
203.
204.
206.
250.
251.
P um p S u c tio n B reaker
P um p Je t
D isch a rg e Passage
P um p P lu n g e r Head
P um p D u ra tio n S p rin g
P um p Lever
P um p S tem Seal R e ta in e r
P um p Stem Seal
P um p P lu n g e r S p rin g
P um p P lu n g e r C up
P um p R eturn S p rin g
P um p D isch a rg e P lug (R etainer)
P um p D isch a rg e Ball
250
F-02717
Figure 28Pump System
6C1-26 CARBURETORS
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
L.
M.
Rich S top A d ju s tin g B u sh in g

(Do n ot tu rn o r remove)
Rich S top A d ju s tin g Plug
Prim ary T h ro ttle Valve
S econdary T h ro ttle Valve
A ir Valve
E cce n tric Cam
M ete rin g D isc
S econdary Fuel W ell
A c ce le ra to r W ell In let O rific e
A cce le ra to r W ell and Tube
A cce le ra to r W ell D ischarge
O rific e
S econdary W ell Bleed Tube
N. Clean A ir Inlet
P. S econdary W ell Bleed A d ju s t Screw
(Do not tu rn o r remove)
Q- S econdary W ell Bleed A d ju s t S pring
R- S econdary W ell Bleed A d ju s t Plug
S. S econdary D ischarge Nozzle
T. B a ffle
31. S econdary M ete rin g Rod H o ld e r
32. S econdary M ete rin g Rod
50. A ir H orn B a ffle
212. Power Valve P iston A s se m b ly
213. Prim ary M ete rin g Rod
218. Power P iston S pring
248. Prim ary M ete rin g Jet
F-02718
Figure 29Power System - M4MEF
CARBURETORS 6C1-27
A.
B.
C.
D.
E.
F.
G.
55.
58.
C ho ke Valve
V acuum B reak A d ju s tin g S crew
Leaf-Type B u c k in g S p rin g
U n lo a d e r Tang
F ast Id le C am F o llo w e r
T h e rm o s ta tic C o il
A ir Valve
P rim a ry S id e V a cuu m B reak A s s e m b ly
P rim a ry S id e V a cu u m B r e a k A ir Valve Lever L in k
356. C hoke L in k
360. S e co n d a ry T h ro ttle L o c k o u t Lever
425. F ast Idle A d ju s tin g S crew
G 58
360
356
425
F-02716
Figure 30Choke System - Electric - M4MEF (With Primary Side Vacuum Break Only)
360
A.
B.
C.
D.
E.
C h o ke Valve
T h e rm o s ta tic C o il
U n lo a d e r Tang
F ast Idle Cam F o llo w e r
P lu n g e r B u c k in g S p rin g
(N o t U sed On A ll M od els)
F. A ir Valve
55. P rim a ry S id e V a cuu m B reak A s s e m b ly

58. P rim a ry S id e V a cuu m B reak to A ir Valve Lever L in k
320. S e c o n d a ry S ide V a cuu m B reak A s s e m b ly
322. S e c o n d a ry S id e V a cu u m B reak To C hoke L in k
356. C h o ke L in k
360. S e c o n d a ry T h ro ttle L o c k o u t Lever
425. F ast Id le A d ju s tin g S cre w
F-01894
Figure 31Choke System - Electric - M4ME (With Primary Side and Secondary Side Vacuum Break)
6C1-28 CARBURETORS
DIAGNOSIS OF M4ME AND M4MEF ROCHESTER

CARBURETOR
T h e fo llo w in g d ia g n o s tic p r o c e d u r e s a r e fo r c a r b u r e to r re la te d p r o b le m s a n d th e ir e ffe c ts o n v e h ic le p e r fo r m a n c e . O t h e r
c a n a ls o c a u s e p r o b le m s a n d s h o u ld b e c h e c k e d w h e n lis te d o n th e c h a rt.
vehicle systems
PROBLEM
Engine Cranks
Normally - Will Not
Start or Starts Hard
POSSIBLE CAUSE

4. Engine loaded with fuel. (Improper start

ing procedure used or choke unloader
mi sad justed.)
5. No fuel in carburetor.
6 . Engine flooded. To check for flooding, re
move the air cleaner and look into the

carburetor venturi for fuel dripping from
nozzles.

Not Keep Running
3. Engine does not have correct fast idle

speed when cold.
CORRECTION
the Ow ners and D rivers M anual , is
used.
3. Check for free movement, and com
plete opening and closing, of choke
valve. See Choke Checking Proce
dure and Checking Electric Choke
the Ow ners and D rivers M anual , is
used.
Adjust choke unloader.
5. Inspect fuel filter(s) for being plugged.
restrictions.
necessary.
C heck float for restricted movement
or being loaded.
Check float needle pull clip location.
Open end of clip should be installed
over float lever cross bar, facing away
from pontoon.
Inspect flo at needle and seat for
wear and for dirt or chips.
necessary.
sary.
1 . Check with the custom er to determ ine

the O w ners and Drivers M anual, is
used.
2 . Check for free movement and complete
See Choke C hecking Procedure and
section.
3. Check for free movement of fast idle
cam and linkage. See Choke Check
ing Procedure later in this section. Ad
ju s t fast idle speed. See Em ission
CARBURETORS 6C1-29

CARBURETOR (CONT.)
PROBLEM
Not Keep Running
(Cont.)
POSSIBLE CAUSE
CORRECTION
4. Vacuum break assembly(s) malfunction

ing or misadjusted.

5. Adjust idle speed. See Emission Con
6 . Use a pressure oil can to spray light oil
surfaces.
sary, replace the carburetor flange gas
ket and/or intake manifold gaskets.
Check condition and routing of vacuum
hoses. Correct or replace as necessary.
7. Inspect fuel filter(s) for being partially
plugged. Replace as necessary.
s p e c t fu e l lin e s fo r le a ks and
restrictions.
necessary.
or being loaded.
from pontoon.
wear and for dirt or chips.
b ureto r. R e p la c e fu e l filte r(s ) as
necessary.
sary.
5. Idle speed too low.

6 . Air leaks at carburetor flange gasket, or
at intake manifold gaskets. Vacuum

hoses disconnected or installed improp
erly.
7. Not enough fuel in carburetor.
8 . Carburetor flooding.
Engine Idles
or Too Slow)
1. Idle speed misadjusted.

2. Idle stop solenoid or throttle kicker
malfunctioning. Faulty solenoid circuit
wiring.
3. Choke not operating properly or fast idle

4. Throttle linkage or throttle shaft(s) stick

ing or binding.
1. Adjust idle speeds. See Emission Con

2. See Idle Stop Solenoid Checking Pro
cedure and Throttle Kicker Checking
Procedure later in this section. Refer
to the Fuel and Emissions Service
Manual.
3., Check choke valve and fast idle cam
section.
4. Check throttle linkage and throttle
shaft(s) for smooth and free operation.
Clean with suitable solvent. Replace
throttle body if necesasry.
6C-30 CARBURETORS

CARBURETOR (CONT.)
Engine Idles
5.
A ir le a k s a t c a r b u r e to r fla n g e g a s k e t, o r
at in ta k e m a n ifo ld g a s k e ts . V a c u u m
h o s e s d is c o n n e c te d o r in s ta lle d im p r o p
e rly .
5.
6.
P C V s y s te m m a lfu n c tio n in g .
6.
7.
Ig n itio n tim in g m is a d ju s te d .
7.
8.
D is trib u to r v a c u u m o r m e c h a n ic a l a d
v a n c e m a lfu n c tio n in g .
Id le s y s te m re s tric te d o r in c o rr e c t id le
m ix tu re a d ju s tm e n t.
R e s tric te d a ir c le a n e r e le m e n t.
C a rb u re to r flo o d in g .
8.
9.
10.
11.
Engine Diesels (After

Run) Upon Shut Off
CORRECTION
POSSIBLE CAUSE
PROBLEM
1.
B a s e id le s p e e d m is a d ju s te d .
2.
Id le s to p s o le n o id o r th ro ttle
m a lfu n c tio n in g . F a u lty s o le n o id
w irin g .
3.
C h o k e n o t o p e r a tin g p ro e p rly o r fa s t id le
c a m s tic k in g o r b in d in g .
4.
T h r o ttle lin k a g e o r th ro ttle s h a ft s tic k in g

o r b in d in g .
5.
A ir le a k s a t c a r b u r e to r fla n g e /in s u la to r
g a s k e t(s ), o r a t in ta k e m a n ifo ld g a s k e t.
V a c u u m h o s e s d is c o n n e c te d o r in s ta lle d
im p ro p e rly .
k ic k e r
c irc u it
9.
10.
11.
U s e a p r e s s u r e o il c a n to s p r a y lig h t o il
o r k e r o s e n e a r o u n d c a r b u e r to r th ro ttle
b o d y (d o n o t s p r a y a t th ro ttle s h a ft
e n d s ), a n d m a n ifo ld to h e a d m o u n tin g
s u rfa c e s .
If e n g i n e R P M c h a n g e s , t o r q u e c a r
b u re to r to m a n ifo ld b o lts a n d /o r in ta k e
m a n i f o l d b o l t s t o s p e c i f i c a t i o n . If n e c e s
sary, re p la c e th e c a rb u re to r fla n g e g a s
ke t a n d /o r in ta k e m a n ifo ld g a s k e t.
C h e c k c o n d itio n a n d ro u tin g o f v a c u u m
h o ses . C o rre c t o r re p la c e a s n e c e s s a ry .
C h e c k P C V s y s te m . C le a n o r re p la c e
P C V v a lv e a n d h o s e s a s n e c e s s a ry .
A d ju s t tim in g . S e e E m is s io n C o n tro l In
fo rm a tio n L a b e l.
C h e c k o p e r a tio n . R e f e r to E N G IN E
E L E C T R IC A L (S E C . 6 D ).
C l e a n c a r b u r e t o r if n e c e s a s r y . A d j u s t
id le m ix tu re p e r s p e c ifie d p r o c e d u r e .
R e p l a c e if n e c e s s a r y .
R e m o v e th e a ir h o rn .
C h e c k flo a t fo r re s tric te d m o v e m e n t
o r b e in g lo a d e d .
C h e c k flo a t n e e d le p u ll c lip lo c a tio n .
O p e n e n d o f c lip s h o u ld b e in s ta lle d
o v e r flo a t le v e r c r o s s bar, fa c in g a w a y
fro m p o n to o n .
In s p e c t flo a t n e e d le a n d s e a t fo r
w e a r , a n d fo r d irt o r c h ip s .
If f o r e i g n m a t e r i a l is f o u n d in t h e c a r
b u re to r, c le a n th e fu e l s y s te m a n d c a r
b u re to r. R e p la c e fu e l filte r(s ) a s
n ecessary.
C h e c k f l o a t l e v e l , a n d a d j u s t if n e c e s
sary.
1. A d j u s t b a s e i d l e s p e e d . S e e E m i s s i o n
C o n tro l In fo rm a tio n L a b e l.
2. S e e I d l e S t o p S o l e n o i d C h e c k i n g P r o
c e d u r e a n d T h ro ttle K ic k e r C h e c k in g
P r o c e d u r e la t e r in t h is s e c t i o n . R e f e r
to th e F u e l a n d E m is s io n s S e r v ic e
M a n u a l.
3. C h e c k c h o k e v a l v e a n d f a s t i d l e c a m
fo r fre e m o v e m e n t. C h e c k fo r c o m p le te
o p e n in g a n d c lo s in g o f c h o k e v a lv e .
S e e C h o k e C h e c k in g P ro c e d u re a n d
C h e c k i n g E l e c t r ic C h o k e l a t e r in th is
s e c tio n .
4. C h e c k t h r o t t l e l i n k a g e a n d t h r o t t l e s h a f t
fo r s m o o th a n d fr e e o p e r a tio n . C le a n
w ith s u ita b le s o lv e n t. R e p l a c e th ro ttle
b o d y if n e c e s s a r y .
5. U s e a p r e s s u r e o i l c a n t o s p r a y l i g h t o i l
o r k e r o s e n e a r o u n d c a r b u r e to r th ro ttle
b o d y (d o n o t s p r a y a t th ro ttle s h a ft
e n d s ), a n d m a n ifo ld to h e a d m o u n tin g
su rfa c e s .
CARBURETORS 6C1-31

CARBURETOR (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Engine Idles
5.
6.
P C V s y s te m m a lfu n c tio n in g .
7. I g n i t i o n t i m i n g r e t a r d e d ( c a u s e s t h r o t t l e
8.
Engine Hesitates
During Normal
Acceleration
* Hesitates During
Cold Engine
Operation.
1.
v a lv e to b e o p e n e d fa r th e r th a n n o r m a l
to o b ta in c o rre c t id le s p e e d ).
L e a n id le m ix tu r e (c a u s e s th ro ttle v a lv e
to b e o p e n e d fa r th e r th a n n o r m a l to o b
ta in c o rr e c t id le s p e e d ).
M a lfu n c tio n in g p u m p s y s te m o r m is a d
ju s te d p u m p .
M a k e a q u ic k c h e c k of th e p u m p s y s
te m : W it h th e e n g in e o ff, lo o k in to th e
c a rb u re to r b o re a n d o b s e r v e p u m p d is
c h a r g e je t s ; a c t u a t e t h r o t t le le v e r . A fu ll
s t r e a m o f fu e l s h o u ld e m it fr o m th e je ts .
2. * C h o k e n o t o p e r a t i n g p r o p e r l y .
3. * V a c u u m
b re a k a s s e m b ly (s )
tio n in g o r m is a d ju s te d .
C o n tin u e d
If e n g i n e R P M c h a n g e s , t o r q u e c a r
b u re to r to m a n ifo ld b o lts a n d /o r in ta k e
m a n i f o l d b o l t s t o s p e c i f i c a t i o n . If n e c e s
sary, re p la c e th e c a rb u re to r fla n g e /in
s u la to r g a s k e t(s ) a n d /o r in ta k e m a n ifo ld
g a s k e t. C h e c k c o n d itio n a n d ro u tin g o f
v a c u u m h o s e s , co rrect o r re p la c e a s
n ecessary.
6. C h e c k P C V s y s te m . C le a n r e p la c e P C V
v a lv e a n d h o s e s a s n e c e s s a ry .
7. A d j u s t t i m i n g . S e e E m i s s i o n C o n t r o l I n
8.
C l e a n c a r b u r e t o r if n e c e s s a r y . A d j u s t
id le m ix tu re p e r s p e c ifie d p r o c e d u r e .
1.
R e m o v e a ir h o rn a n d c h e c k p u m p c u p .
If c r a c k e d o r h a r d e n e d , r e p l a c e t h e
p u m p p lu n g e r c u p a n d s p rin g .
C h e c k fo r re s tric te d p u m p p a s s a g e s .
C le a n a n d b lo w o u t p a s s a g e s w ith
c o m p r e s s e d a ir.
C h e c k th e p u m p d is c h a r g e b a ll fo r
p ro p e r s e a tin g .
A d ju s t p u m p to s p e c ific a tio n .
C h e c k fo r c o m p le te o p e n in g a n d c lo s
i n g o f c h o k e v a l v e . S e e C h o k e C h e c k
in g P r o c e d u r e a n d C h e c k in g E le c tric
C h o k e l a t e r in t h is s e c t i o n .
S e e V a c u u m B r e a k C h e c k i n g P r o c e
d u r e la t e r in t h is s e c t i o n . A d j u s t v a c
u u m b re a k (s ) to s p e c ific a tio n .
C h e c k o p e r a tio n . R e fe r to th e F u e l
a n d E m is s io n s S e rv ic e M a n u a l.
C h e c k o p e r a tio n . R e fe r to th e F u e l
a n d E m is s io n s S e rv ic e M a n u a l.
A d ju s t tim in g . S e e E m is s io n C o n tro l In
C h e c k o p e r a tio n . R e fe r to E N G IN E
E L E C T R IC A L (S E C . 6 D ).
C h e c k f l o a t l e v e l , a n d a d j u s t if n e c e s
sary.
C h e c k p o w e r p is to n o p e r a tio n : p u s h
p i s t o n d o w n a n d r e l e a s e ; it s h o u l d
m o v e f r e e l y in b o r e a n d r e t u r n to its u p
p o s itio n .
If p i s t o n d o e s n o t m o v e f r e e l y , c l e a n
p o w e r p is to n a n d b o re .
If p i s t o n d o e s n o t r e t u r n w h e n r e
le a s e d , c h e c k fo r m is s in g o r d a m a g e d
p o w e r p i s t o n s p r i n g . R e p l a c e if n e c e s
sary.
In s p e c t m e te rin g rod h a n g e r fo r d a m
a g e . R e p l a c e p o w e r p i s t o n a s s e m b l y if
necessary.
2.
m a lfu n c
3.
4. * T h e r m a e s y s t e m m a l f u n c t i o n i n g .
4.
5. * E a r l y F u e l E v a p o r a t i o n ( E F E ) s y s t e m
5.
6.
m a lfu n c tio n .
Ig n itio n tim in g m is a d ju s te d .
7. D i s t r i b u t o r v a c u u m
8.
or
v a n c e m a lfu n c tio n in g .
F l o a t le v e l t o o lo w .
m e c h a n ic a l
6.
ad
9. P o w e r p i s t o n s t i c k i n g . M i s s i n g o r d a m
7.
8.
9.
a g e d p o w e r p is to n s p rin g .
10.
P rim a ry m e te rin g rod h a n g e r b e n t.
10.
6C1-32 CARBURETORS
DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER

PROBLEM
Engine Hesitates On
Acceleration (Cont.)
Engine Has Less Than

Normal Power At
Normal Acceleration
POSSIBLE CAUSE
11. Restricted primary metering jets.

2. Ignition tim ing misadjusted.

malfunction.
8 . Transmission malfunction.

11. Faulty fuel pump, or leaking or restricted
fuel lines.
aged power piston spring.
14. Primary metering rod hanger bent.
15. Primary metering jets restricted or loose.
CORRECTION
re to r. R e p la c e fu e l filte r ( s ) as
necessary.
2. Adjust tim ing. See Emission Control In
formation Label.
3. C heck operation. Refer to ENG INE
4. Replace element.
5. C heck retrictions. Correct as neces
sary.
8 . Refer to transm ission diagnosis.
sary.
essary.
piston down and release; it should
move freely in bore and return to its up
position.
If piston does not return when re
leased, check for missing or damaged
power piston spring. Replace if neces
sary.
necessary.
re to r. R e p la c e fu e l filte r ( s ) as
necessary. If m etering jets are loose,
tighten.
CARBURETORS 6C1-33

PROBLEM
Less Than Normal
Power On Heavy
Acceleration Or At
High Speed
POSSIBLE CAUSE
CORRECTION
1. Throttle valves not opening completely,

or secondary throttle valves not opening.
1. Correct throttle linkage to obtain wide
2.
3.

tioning.
6 . Exhaust system restricted.
7. Thermae system malfunction.
4.
8 . Early fuel Evaporation (EFE) system mal
8.
function.
9. Transmission malfunction.
10 . Choke not operating properly.
5.
6.
7.
9.
10.
11. Secondary air valve shaft, valves, or air

valve link sticking or binding.
11.
12. Air valve link misadjusted. (May cause

h e sita tio n when se con da ry th ro ttle
valves are opened.)
13. Vacuum break assembly malfunctioning.
(May cause hesitation when secondary
throttle valves are opened.)
14. Air valve return spring broken or misad
justed.
15. Secondary metering rod holder bent.
12.

fuel lines.
18. Float level too low. Float needle pull clip
missing or installed incorrectly.

open throttle.
Check secondary throttle lockout
lever for sticking or incorrect adjust
ment. Clean or repair as necessary. Ad
just lockout lever to specification.
Check ignition system. Refer to EN
Adjust timing. See Emission Control In
formation Label.
Check operation. Refer to ENGINE
Replace element.
Check for restrictions. Correct as necessary.
Refer to transmission diagnosis.
Check for complete opening and clos
Check air valves for smooth operation.
Clean, repair, or replace air horn and
air valve link as necessary.
Adjust air valve link to specification.

dure later in this section.
14. Replace air valve return spring if nec
essary. Adjust spring to specification.
15. Check holder for damage. Replace if
necessary.
16. Inspect fuel filter(s). Replace as necessary.
essary.
Check for presence of float needle
pull clip. Replace if necessary. Open
end of clip should be installed over float
lever cross bar, facing away from pon
toon.
position.
If piston does not return when released,
check for missing or damaged power piston
spring. Replace if necessary.
necessary.
6C1-34 CARBURETORS

PROBLEM
Less Than Normal
Power On Heavy
Acceleration Or At
High Speed (Cont.)
Engine Surges
POSSIBLE CAUSE
21. Primary metering jets restricted or loose.
Secondary metering discs restricted or
m issing. Secondary accelerator well
tubes restricted. (Will cause hesitation
when secondary th ro ttle valves are
opened.)

tioning.
3. Air leaks at carburetor flange gasket, or
at intake m anifold gaskets. Vacuum
erly.
4. PCV system malfunctioning.


malfunction.
8 . Contaminated fuel.
fuel lines.
12. Float needle sticking in seat.


15. Restricted primary metering jets.
CORRECTION
retor. R e p la ce fu e l filte r(s ) as
necessary.
If the primary metering jets are loose,
tighten. If secondary metering discs are
missing, replace float bowl.
surfaces.
essary.
8 . Check for water or excessive alcohol in
fuel.
sary.
essary.
12. Replace float needle and seat.
position.
If piston does not return when re
leased, check for missing or damaged
power piston spring. Replace if neces
sary.
necessary.
retor. R e p la ce fu e l filte r(s ) as
necessary.
CARBURETORS 6C-35

PROBLEM
Poor Gas Mileage
* Black Smoke From
Tail Pipe
POSSIBLE CAUSE
1. Customer driving habits.
2. Wrong speedometer gear.
3. Low tire pressure or incorrect tire size.

4. Transmission malfunction or in wrong
gear.
5. Fuel leaks.
6 . * Plugged air cleaner element.
7. * Choke not operating properly.
8 . * Vacuum break assembly malfunction
ing or misadjusted.
12. Air leaks at carburetor flange gasket, or
at intake m anifold gaskets. Vacuum
erly.
13. Engine in need of service.

15. * High fuel level in carburetor or flood
ing.
CORRECTION
1. Run mileage test, with customer driving
if possible, make sure vehicle has
2000-3000 miles (3 200-4 800 km) for
the break-in period.
2. Check odom eter against measured
mile. Replace speedometer gear if nec
essary.
3. Inflate tires to specifications and use
correct tire sizes.
5. Inspect fuel tank, fuel lines and fuel
pump for any fuel leakage.
6 . Replace element.
8 . See Vacuum Break Checking Proce
formation Label.
surfaces.
buretor manifold bolts and/or intake
13. Check engine compression.
essary.
15. Check float for restricted movement or
being loaded.
from pontoon.
Check float needle and seat for wear
and dirt or chips.
If foreign material is found in carbure
tor, clean fuel system and carburetor.
Replace fuel filter(s) as necessary.
sary.
6C1-36 CARBURETORS

PROBLEM
Poor Gas Mileage
(Cont.)
16. Power piston s tickin g . Power piston

spring stretched.
18. * Worn or damaged prim ary metering

rods. Worn or damaged secondary me
tering rods (black smoke when second
ary throttle valves are opened).
19. * Primary metering jets worn or loose.
Secondary metering discs worn or miss
ing (black smoke when secondary throt
tle valves are opened).
Gasoline Odor

position.
Check power piston spring for dam
age. Replace if necessary.
necessary.
18. Inspect prim ary and secondary me
tering rods. Replace as necessary.
19. Inspect metering jets. Replace if neces

sary. If loose, tighten. If loose, tighten.
Inspect secondary metering discs. If
worn or missing, replace float bowl.
6 . Faulty fill cap.
1. Repair/replace as required.
2. Purge tank and repair or replace tank
as required.
3. Connect, repair/replace lines as re
quired.
4. Connect, clean, or reroute lines as re
quired.
5. Compare weight of canister with a new
one. Replace if necessary.
6 . Install new cap.
1. Fuel filter(s) plugged.
1 . Inspect fuel filter(s). Replace as neces
2. Fuel lines leaking, restricted, or misrouted.

3. Faulty fuel pump.
2 . Repair/replace, clean, or reroute as re
1. Fuel feed or vapor return line leaking.

2. Leak in fuel tank.
3. Disconnected or leaking fuel tank vent
lines or hoses to canister(s).
4. Purge lines not connected, improperly
routed, plugged or pinched.
5. Carbon canister(s) loaded.
Fuel Starvation
CORRECTION
POSSIBLE CAUSE
sary.
quired.
Replace pump if necessary.
CARBURETORS 6C1-37
ON-VEHICLE SE R V IC E (MODELS M4ME AND M 4M EF)
A. Pump Cup or Valve Stem

B. Tape Hole in Tube
C. Tape End o f Cover
B-06210
Figure 32 Float Level - External Check
FLOAT LEVEL - EXTERNAL CHECK

Tool Required:
J-34935-1 External float Level Gage
1. W ith the engine idling and the choke valve wide
open, insert J-34935-1 in the vent slot or vent hole
(figure 32).
Allow the gage to float freely.
NOTICE: Do not press dow n on the gage.
Flooding or float damage could result.
2. Observe the mark on the gage that lines up with the
top of the casting. The setting should be within
1.588mm (2/32-inch) of the specified float level
setting.
Incorrect fuel pressure will adversely affect the
fuel level.
3. If not within specification, remove the air horn and
adjust the float.
CHOKE CHECKING PROCEDURE (ENGINE OFF)

1. Remove the air cleaner assembly.
2. Hold the throttle half way down.
3. Open and close the choke several times. Be sure all
links are connected, and are not damaged. Choke
valve, linkage, and fast idle cam must operate freely.
If the choke valve, linkage, or fast idle cam is
sticking due to varnish, clean with choke
cleaner X-20-A or equvialent.
Do not lubricate linkage, as lub rica nt w ill
collect dust and cause sticking.
Figure 33 Plugging Vacuum Break Bleed Holes

CHECKING ELECTRIC CHOKE - ON VEHICLE
1 . Allow the choke stat to stabilize at about 21 C
(70 F).
2. Open the throttle, to allow the choke valve to close.
3. Start the engine, determ ine the length of tim e for the
choke valve to reach full open position:
If longer than five minutes, check the voltage
at the choke stat connector, with the engine
running:
If voltage is between 12 and 15 volts:
Check for proper ground between choke
cover and choke housing. If correct,
replace choke cover assembly.
If the voltage is low or zero: Check all
wires and connections. Refer to ENGINE
VACUUM BREAK CHECKING PROCEDURE

Tool Required:
J-23738-A, Hand Operated Vacuum Pump
1. If the vacuum break has an air bleed hole, plug it
during this checking procedure (figure 33).
2. Apply -51 kPa (15 in. Hg.) vacuum to the vacuum
break.
Apply finger pressure to see if the plunger has
moved through full travel. If not, replace the
vacuum break.
Observe the vacuum gage. Vacuum should
hold vacuum for at least twenty seconds. If
not, replace the vacuum break.
3. Replace vacuum break hoses that are cracked, cut
or hardened.
CHECKING IDLE STOP SOLENOID (ISS)

A non-functioning idle stop solenoid (ISS) (if equipped)
could cause stalling or rough idle.
1. Turn the igntion on but do not start the engine.
2. Open the throttle mom entarily to allow the solenoid
plunger to extend.
6C1-38 CARBURETORS
FUEL INLET
/
NUT
GASKET
FILTER (WITH
CHECK VALVE) SPRING
F-01899
Figure 35Fuel Inlet Nut and Filter
3. Disconnect the wire at the solenoid. The plunger

should drop back from the throttle lever.
4. Connect the solenoid wire. The plunger should
move out and contact the throttle lever.
5. If the plunger does not move in and out as the wire
is disconnected and connected, check voltage
across the feed wire.
If the voltage is 12 to 15 volts, replace the
solenoid.
If the voltage is low, locate the cause of the
open circuit in the solenoid feed wire; repair as
necessary.
CHECKING THROTTLE KICKER

Tool Required:
J-23738-A, Hand Held Vacuum Pump
1. Hold the throttle half way open to allow the plunger
to extend fully.
2. Apply - 6 8 (20" Hg) vaucum to the throttle kicker
(figure 34).
Apply finger pressure to the plunger to see if it
has extended fully. If not, replace the throttle
kicker.
Observe the vacuum gage. Vacuum should
hold for at least twenty seconds. If not, replace
the throttle kicker.
3. Release the vacuum to the throttle kicker.
If the plunger does not retract to its starting
position, replace kicker.
The filter must include an inlet check valve to

m e e t M o to r V e h ic le S a fe ty S ta n d a rd s
(M.V.S.S.) for roll-over.
The check valve end of the filter must face the
fuel line.
4. Fuel inlet nut.
Tighten
Inlet nut to 62 N-m (46 ft. lbs.).
5. Fuel line to inlet nut.
Start engine and check for leaks.
CARBURETOR MOUNTING
TORQUE
After servicing, tighten m ounting bolts, in a clockwise
direction, to 16 N m (144 in. lbs.). When retightening
carburetor at recommended maintenance intervals, check
in clockwise direction. If less than 7 N m (60 in. lbs.),
retighten to 11 N-m (96 in. lbs.); but if greater than 7 N-m
(60 in. lbs.), do not retighten.
CARBURETOR REPLACEMENT
F lo o d in g , s tu m b le on a c c e le r a tio n a nd o th e r
performance complaints are, in many instances, caused
by the presence of dirt, water or other foreign matter in
carburetor. To aid in diagnosing the cause, the carburetor
should be removed carefully from the engine without
draining fuel from the bowl. Contents of the fuel bowl then
may be examined for foreign m aterials as the carburetor
is disassembled.

1. Fuel line connection at the fuel inlet nut.
2. Fuel inlet nut.
3. Fuel inlet filter, gasket, and spring.
[-+[ Install or Connect (Figure 35)

1. Fuel filter spring in float bowl.
2. New gasketon inlet nut.
3. Fuel inlet filter in inlet nut.
1 . Negative battery terminal.

2. Air cleaner assembly and gasket.
3. Electrical connectors from the choke and idle stop
solenoid.
4. Vacuum hoses.
Make note of the vacuum hose routing.
6 . Downshift cable (automatic transm ission only).
7. Cruise control linkage (if equipped).
8 . Fuel line connection at the fuel inlet nut.
9. Carburetor attaching bolts.
10. Carburetor and flange insulator.
CARBURETORS 6C1-39
Clean
S e alin g su rfa c e s on th e intake m an ifo ld and
carburetor.
CAUTION: Extinguish all open flames while

filling and testing carburetor with gasoline to
avoid personal injury.
+ + Install or Connect
1. Carburetor with new flange gasket.
It is good shop practice to fill the carburetor

float bowl before installing the carburetor. This
reduces the strain on sta rtin g m otor and
b a tte ry and re d u c e s th e p o s s ib ility o f
backfiring while attempting to start the engine.
Operate the throttle several tim es and check
the discharge from pump jets before installing
the carburetor.
Carburetor attaching bolts.
Figure 36Removing idle Mixture Needle Plugs
Tighten
Bolts to 16 N-m (144 in. lbs.)
Tighten in a criss-cross pattern.
3. Fuel line to the fuel inlet nut.
4. Cruise control cable (if equipped).
5. Downshift cable (automatic transm ission only).
6 . Accelerator linkage.
7. Vacuum hoses.
Refer to the Emission Control Inform ation
Label for vacuum hose routing information.
8 . Electrical connectors to the choke and idle stop
solenoid.
9. Air cleaner assembly with gasket.
10. Negative battery terminal.
Adjust
Idle mixture and idle speeds.
5.
6.
7.
IDLE MIXTURE ADJUSTMENT

(HEAVY DUTY EMISSION
VEHICLES ONLY)
In case of a major carburetor overhaul, throttle body
replacement, or high idle CO (when indicated by an
emissions inspection), the idle m ixture may be adjusted.
Adjusting the mixture by other than the following method
may violate Federal and/or state laws (figures 36 through
38).
8.
9.
10.
11.
Tool Required:
J-29030-B Idle Mixture Needle Socket.
1. Set parking brake and block drive wheels.
12.
2. Remove the carburetor from the engine.

3. Drain fuel from the carburetor into a container.
Dispose of the fuel in an approved container.
4. Remove idle m ixture needle plugs (figure 36):
Invert the carburetor and support it to avoid
damaging external components.
13.
Make two parallel hacksaw cuts in the throttle

body, between the locator points near one idle
mixture needle plug. The distance between
the cuts depends on the size of the punch to
be used.
Cut down to the plug, but not more than
1 / 8 -inch beyond the locator point.
Place a flat punch at a point near the ends of
the saw marks. Hold the punch at a 45 degree
angle and drive it into the throttle body until
the casting breaks away, exposing the steel
plug.
Use a center punch to break the plug apart,
uncover idle m ixture needle.
Remove all loose pieces of plug.
Repeat the previous steps for the other needle
plug.
Use J-29030-B to ligh tly seat the idle m ixture
needles, then back out three turns.
Reinstall carburetor on the engine.
Place tra n sm issio n in P (PARK) (au tom a tic
tr a n s m is s io n ) o r N (N E U T R A L ) (m a n u a l
transmission).
Start the engine and bring it to a normal operating
temperature, choke valve open, and air conditioning
off.
C onnect a know n a ccurate ta ch o m e te r to the
engine.
Check ignition tim ing, and adjust if necessary, by
following the procedure described on the Emission
Use J-29030-B to turn the mixture needles equally
( 1/8 turn at a time), in or out, to obtain the highest
RPM (best idle).
Adjust the idle speed screw (throttle stop) to obtain
the base idle speed specified on the Emission
Again try to readjust mixture needles to obtain the
highest idle RPM.
The adjustm ent is correct when the highest RPM
(best idle) is reaches with the minimum num ber of
mixture needle turns from the seated position.
6C1-40 CARBURETORS
Figure 37Fast Idle Adjustment

14. If necessary, readjust the idle speed screw (throttle
stop) to obtain the specified base idle speed.
15. C heck, (and if necessary, adjust), idle speed
solenoid activated speed, and fast idle speed. Refer
to figures 38 and 39 and the Emission Control
Emission Information label.
16. Check the throttle kicker (TRC RPM), and adjust if
necessary. R efer to the Fuel and E m issions
Service M a n u a l and to the Em ission Control
Information label.
17. Turn off the engine, and remove the block from the
drive wheels.
IDLE SPEED ADJUSTMENT

Refer to figures 37 through 39 and the Emission Control
Information label to adjust idle speed, idle speed solenoid
activated speed, and fast idle speed.
THROTTLE KICKER ADJUSTMENT

Refer to the Fuel and Emissions Service M anual to
adjust the throttle kicker.
FLOAT ADJUSTMENT
Tools Required:
J-9789-90, Float Level T Scale
J-34817, Float Positioning Tool Kit
1. Remove the air horn, gasket, power piston and
metering rod assembly, and the float bowl insert

(figure 40).
2. Attach J-34817-1 to the float bowl.
3. Place J-34817-3 in J-34817-1 with the contact pin
resting on the outer edge of the float lever.
4. Measure the distance from the top of the casting to
the top of the float at a point 3/16-inch from the large
end of the float.
Use J-9789-90.
Figure 38Idle Speed Adjustment - Without Idle Speed Solenoid
CARBURETORS 6C1-41
Make sure Pump

Link is in specified hole.
(2) With Fast Idle Cam off Cam Follower Lever,

turn Throttle Stop Screw out so it does not
touch Throttle Lever.
(3) Measure distance from top of Choke Valve
wall to top of Pump Stem.
(4) Adjust, if necessary, by supporting Pump
Lever at () and bending at notch.
PUMP ADJUSTMENT
A. S o le n o id S crew
B. Id le Speed S crew
C. E le c tric a l C o n n e c tio n
B-09284
F-02714
Figure 39Fast Idle Adjustment
J-34817-25
or
BT-8427
J-9789-90
or
BT-8037
Figure 41Pump Adjustment
J-34817-3
or
BT-8227A
J-34817-1
or
BT-8227A-1
5. If more than 2/32-inch from specification, use

J-34817-25 to bend the lever up or down.
Remove J-34817-25 and measure, repeating
until within specification.
6 . Check the float alignment.
7. Reassemble the carburetor.
PUMP ADJUSTMENT
1.
2.
3.
4.
Tool Required:
J-9789-90, Float Level T Scale
The pump link (410) must be in the specified hole
(figure 41).
With the fast idle cam off the cam follower lever, turn
the throttle stop screw (380) out so it does not touch
the throttle lever.
Measure the distance from the top of the choke
valve wall to the top of the pump stem.
Adjust, if necessary, by supporting the pump lever
(41) with a screwdriver and bending it at the notch.
AIR VALVE RETURN SPRING

ADJUSTMENT
F-02715
Figure 40Float Adjustment
1. Loosen the setscrew (figure 42).

2. a. Turn spring flucrum pin counterclockwise until
the air valves open,
b. Turn the pin clockwise until the air valves close,
then the additional turns specified.
3. Tighten the setscrew.
4. Apply lithium grease to the spring contact area.
6C1-42 CARBURETORS
Loosen set screw .
(2a)Turn Spring Fulcrum

Pin Q until Air Valves ()
open.
(2^)Turn pin Q until Air Valves
close, then additional turns
specified.
( 3) Tighten set screw.
(4) Apply Lithium grease to spring
contact area.
F-01927
Figure 42Air Valve Return Spring Adjustment
CHOKE STAT LEVER

ADJUSTMENT
1.
2.
3.
4.
5.
Tool Required:
J-9789-111, Linkage Bending Tool
Drill out and remove the choke cover attaching
rivets. Remove choke cover and stat assem bly
(figure 43).
Place fast idle cam on high step against the cam
follower lever.
Push up on the choke stat lever to close the choke
valve.
C heck the stat lever for correct o rientation by
inserting a 0 .120 -inch plug gage hole in the choke
housing.
The gage should fit in the hole and touch the
edge of the lever.
Adjust, if necessary, by bending the choke link with
J-9789-111.
CHOKE LINK AND FAST IDLE CAM

ADJUSTMENT
Tool Required:
J-26701-A, Choke Valve Angle Gage
1. Attach a rubber band to the vacuum break lever of
the intermediate choke shaft (figure 44 and 45).
2. Open the throttle to allow the choke valve to close.
3. Set up J-26701-A and set the angle to specification.
Rotate the degree scale until zero is opposite
the pointer.
Center the leveling bubble.

Rotate the scale to the specified angle.
4. Place the fast idle cam on the second step against
the cam follower lever, with the lever contacting the
rise of the high step. If the lever does not contact the
cam, turn the fast idle adjusting screw in additional
turn s).
Im portant
Final Fast Idle Speed Adjustm ent must be

performed according to the Emission Control
Information label.
5. Adjust, if bubble is not recentered, by bending the
fast idle cam kick lever with pliers.
PRIMARY SIDE VACUUM

BREAK ADJUSTMENT
Tools Required:
1. Attach rubber band to the vacuum break lever of the
intermediate choke saft (figures 44, 46 47).
3. Set up J-26701 and set angle to specifications.
the pointer.
CARBURETORS 6C1-43
If riveted, drill out and remove

rivets. Remove Choke Cover
and Stat Assembly.
J-9789-111 or
BT-3006M
(2) Place Fast Idle Cam on high

step against Cam Follower
Lever.
(3) Push up on Choke Stat Lever
to close Choke Valve.
(4) Check Stat Lever for correct
orientation by inserting .120"
plug gage in hole.
Gage should fit in hole and
touch edge of lever.
(5) Adjust, if necessary, by
bending Choke Link.
F-01928
Figure 43Choke Stat Lever Adjustment
0 Attach Angle Gage Magnet to

closed Choke Valve.
J-26701-A
' /
y '
r
BT-7704
(D Rotate degree scale until zero

is opposite pointer.
(3) Center the leveling bubble.
(4) Rotate scale to specified angle.
(5) Open Choke Valve as
described.
Adjust linkage if bubble is not
recentered.
F-01929
Figure 44Choke Valve Angle Gage
6C1-44 CARBURETORS
4.
P lu g v a c u u m b re a k b le e d h o le s , if
applicable.
Apply -51 kPa (15-inches Hg) vacuum to seat
the vacuum break plunger.
Seat bucking spring, if applicable.
If necessary, bend the air valve link to permit
full plunger travel, then reapply vacuum to
fully retract plunger.
5. Adjust, if bubble is not recentered, by turning the
vacuum break adjusting screw.
SECONDARY SIDE VACUUM

BREAK ADJUSTMENT
Tools Required:
the intermediate choke shaft.
3. Set up J-26701 and set angle to specification (figure
44).
the pointer.
Figure 45Choke Link - Fast Idle Cam Adjustment
P L U G G IN G A IR B L E E D H O L E S
T APE HOLE
IN TUBE
PUMP CUP
OR VALVE
STEM S E A L
T APE END
OF COVER
B U C K IN G S P R IN G S
S p rin g
S e a te d
( S p r in g C o m p r e s s e d )
PLUNGER B UC K IN G SPRING
LEAF TYPE B U C K IN G SPR IN G
F-01931
Figure 46Vacuum Break Adjustment Information
CARBURETORS 6C1-45
4.
P lu g
applicable.
vacuum
b re a k
b le e d
h o le s ,
if
Apply - 51 kPa (15-inches Hg) vacuum to seat

the vacuum break plunger.
C om press the p lu n g e r b ucking sp rin g , if
applicable.
If necessary, bend the air valve link to permit
full plunger travel, then reapply vacuum to
fully retract the plunger (figures 46 and 47).
5. Adjust, if bubble is not recentered, by either:
Supporting the link where shown, and bending
it with J-9789-111. Or
turning screw with a 1 / 8 -inch hex wrench.
AIR VALVE LINK ADJUSTMENT
Figure 48Secondary Side Vacuum Break Adjust

ment
UNLOADER ADJUSTMENT
Tools Required:
the intermediate choke shaft (figures 44 and 50).
Tools Required:
1. Plug vacuum break bleed holes, if applicable. With
the air valves closed, apply -51 kPa (15-inches Hg)
vacuum to seat the vacuum break plunger (figure 46
and 49).
3. Set up J-26701-A and set angle to specifications.
2 . Gage the clearance between the air valve link and
4. Hold the secondary lockout lever away from the pin.
the end of the slot in the air valve lever. Clearance

should be 0.025-inch.
3. Adjust, if necessary, by bending link with J-9789-111.

the pointer.
5. Hold the throttle lever in wide open position.

6 . Adjust, if bubble is not recentered, by bending fast
idle lever with J-9789-111.
6C1-46 CARBURETORS
Figure 49Air Valve Link Adjustment
SECONDARY THROTTLE LOCKOUT

ADJUSTMENT
1. Place the fast idle cam on the high step against the
cam follower lever (figure 51).
5. Push down on tail of fast idle cam to move lockout

lever away from pin.
6 . Rotate the throttle lever to bring the lockout pin to
the position of minimum clearance with the lockout

lever.
2. Hold the throttle lever closed.

3. Gage the clearance between the lockout lever and
pin. It must be 0.015-inch 0.005-inch.
4. Adjust, if necessary, by bending pin.
7. Gage the clearance between the lockout lever and

pin. The minimum must be 0.015-inch.
8 . Adjust, if necessary, by filing the end of the pin.
0 Attach rubber band to Vacuum

Break Lever of Intermediate
Choke Shaft.
(2) Open Throttle to allow Choke
Valve to close.
(3) Set up Angle Gage and set to
specification.
(4) On Quadrajet, hold Secondary
Throttle Lockout Lever away
from pin (g).
(5) Hold Throttle Lever in wide
open position.
(6) Adjust, if bubble is not
recentered, by bending Fast
Idle Lever.
F-01936
Figure 50Unloader Adjustment
CARBURETORS 6C1-47
SPECIFICATIONS
MODEL 1ME AND 1MEF CARBURETORS
Carburetor
Part
No.
Float
Level
mm (Inches)
Metering
Rod
mm (Inches)
Choke Coil
Lever
mm (Inches)
Choke Rod
Cam Adj
mm (Inches)
Vacuum
Break
mm (Inches)
Unloader
mm (Inches)
17086101
17086102
8.7 (11/32)
8.7 (11/32)
2.3 (0.090)
2.3 (0.090)
.120
.120
7.0 (0.275)
7.0 (0.275)
5.0 (0.200)
5.0 (0.200)
13.2 (0.520)
13.2 (0.520)
MODEL M4MC/M4ME CARBURETORS

Fast
Air
Choke
Idle Cam
Vacuum
Vacuum
Air
retor
Level
Rod
Rod
Valve
Coil
Choke
Break
Break
Valve
Part
mm (inches)
Setting
Location
Spring
Lever
Rod
Front
Rear
Rod
No.
2/32"
mm (Inches)
2.5
2.5
3.5
17085000
9.5 (12/32)
7.0 (9/32)
Inner
7/8
.120
O
CO
O
CVJ
17085001
9.5 (12/32)
7.0 (9/32)
Inner
.120
17085003
10.0 (13/32)
7.0 (9/32)
Inner
7/8
17085004
10.0 (13/32)
7 .0 (9/32)
Inner
7/8
17085212
10.0 (13/32)
7.0 (9/32)
Inner
7/8
17085213
10.0 (13/32)
7 .0 (9/32)
Inner
7/8
mm (Inches)
Speed
0 .6 (0.025)
0.6 (0.025)
CO
Enrich
ment
23
.120
46
27
0.6 (0.025)
35
.120
46
O
CO
CVJ
0.6 (0.025)
35
.120
46
23
0.6 (0.025)
35
.120
46
0.6 (0.025)
35
-*>1
o
46
ro
(Turns)
Propane
Unloader
O
O
Pump
o
o
Pump
O
O
Float
O
O
CO
Carbu
6C1-48 CARBURETORS
SPECIAL TOOLS
1.
J-29030-B
5.
J-23738-A
6.
J-9789-111
7.
J-26701-A
J-34817-A
J-9789-90
J-34935-1
1.
2.
3.
4.
5.
6.
7.
Id le M ix tu re N e e d le S o c k e t
F lo a t P o s itio n in g Tool K it
F lo a t Level T S ca le
E xte rn a l F lo a t Level G age
H and O p e ra te d V a cu u m P um p
L in k a g e B e n d in g Tool
C h o ke Valve A n g le G age
F-02708
6C2-1
SECTION 6C2
DIESEL FUEL INJECTION

CONTENTS
SUBJECT
PAGE
Description.................................................................................................................................................................. 6C2- 1
On-Vehicle S e rvice .................................................................................................................................................... 6C2- 2
Fuel Filter R eplacem ent........................................................................................................................................6C2- 2
Idle Speed A d ju stm e n t..........................................................................................................................................6C2- 3
Throttle Position Switch Adjustment (LH6 Engine With 700 R4 Transm ission)........ .............................. 6C2- 3
Vacuum Regulator Valve Adjustment (LL4 Engine With Automatic Transmission)
................................. 6C2- 4
Housing Pressure Cold A d va n ce ......................................................................................................................... 6C2- 4
Injection Line R eplacem ent..................................................................................................................................6C2- 4
Injection Pump Replacem ent................................................................................................................................6C2- 5
Injection Timing Adjustment..................................................................................................................................6C2- 8
Marking TDC On The Front H o u sing ................................................................................................................... 6C2- 8
Injection Nozzles........................................................................................................................................................ 6C2-10
Injection Nozzle Replacement................................................................................................................................6C2-10
Injection Nozzle T e sts................................. ....................................................................................................... 6C2-10
Injection Pump On-Vehicle Service......................................................................................................................... 6C2-12
Pump Cover Seal and/or Guide Stud Seal Replacement.................................................................................. 6C2-12
Minimum-Maximum Governor Replacement....................................................................................................... 6C2-13
Throttle Shaft Seal Replacement......................................................................................................................... 6C2-14
Shutdown And/Or Cold Advance Solenoid Replacem ent................................................................................ 6C2-16
Side Cover Gasket Replacem ent......................................................................................................................... 6C2-17
Injection Pump Off-Vehicle Service......................................................................................................................... 6C2-17
Advance Pin Hole Plug Seal Replacem ent......................................................................................................... 6C2-17
Advance Piston Seals Replacement..................................................................................................................... 6C2-17
Advance Piston Replacement................................................................................................................................6C2-18
Hydraulic Head Seal Replacement................................................................................ .......................................6C2-18
Drive Shaft Seal Replacem ent..............................................................................................................................6C2-19
Pressure Testing The Injection P um p................................................................................................................. 6C2-19
S pecifications............................................................................................................................................................ 6C2-20
Special T o ols.............................................................................................................................................................. 6C2-21
./
DESCRIPTION
The 6.2 L diesel engine fuel system is composed of:
Fuel tank
Mechanical fuel pump
Fuel filter with water sensor and heater
Fuel filter restriction switch
Injection distributor pump
High pressure lines
Fuel injection nozzles
Fuel is drawn from the fuel tank by the mechanical
pump which is located on the right side of the engine. The
pump is driven by an eccentric lobe on the camshaft
through a push rod. Fuel is then pumped through the filter
/ water spearator. The filter / water separator is located on
the engine side of the cowl (R-V models) or under the rear
of the air cleaner (G-P models). The fuel is then trans
ferred to the injection pump.
The injection pump is mounted on top of the engine

under the intake manifold. The pump is driven by the
camshaft through two gears, one attached to the front of
the camshaft and the other attached to the end of the
injection pump shaft. These gears are the same size and
have the same number of teeth; therefore, the injection
pump shaft turns at the same speed as the camshaft. The
pump turns in the opposite direction of the camshaft and
crankshaft.
The injection pump is a high pressure rotary type pump
that meters, pressurizes, and distributes fuel to the eight
injector nozzles. The eight high pressure lines are all the
same length although their shape may be different. This
prevents tim ing differences between cylinders. Injection
lines should not be bent to ease removal.
6C2-2 DIESEL FUEL INJECTION
ON-VEHICLE SERVICE

The fuel filter on R-V models is located on the engine
side of the cowl.
The fuel filter on G-P models is mounted on the rear of
the inlet manifold under the air cleaner. It is accessible by
removing the engine cover.

The fuel tank cap to release pressure or vacuum in the
tank.
The bail wires (1) using a screwdriver.
Drain fuel from the filter by opening both the air
bleed and water drain valves and allowing fuel to
drain into an appropriate container.
Filter.
Any dirt from the fuel port sealing surface of the filter
adapter and the new filter.
4-
1.
2.
3.
New filter.
The bail wires.
Close the water drain valve and open the air bleed.
A 3.18 mm (1/s inch) inside diameter hose to the air
bleed port and the other end into a suitable container.
Disconnect the fuel injection pump shut off solenoid
wire.
NOTICE: If the engine is to be cranked, or start

ing attem pted with the air cleaner removed,
care must be taken to prevent material from be
ing p ulled into the air inlet m anifold which
could result in engine damage.
Crank the engine for 10-15 seconds and then wait one
minute for the starter motor to cool. Repeat until clear
fuel is observed coming from the air bleed.
DIESEL FUEL INJECTION 6C2-3
A.
B.
C.
D.
E.
F.
G.
Front
C lo ckw ise R otation
Power Test Light O r O hm m eter
IGN (Pink Wire)
EGR (Yellow Wire)
O p tio n al Test Location
EPR (Blue o r V io le t Wire)
6 . Open the throttle momentarily to energize and fully
extend the fast idle solenoid plunger.

7. Adjust the extended plunger (3) by turning the hex
head to obtain the fast idle speed shown on the
8 . Remove the jumper wire and install the connector to
F-00008
Figure 4Testing the TPS for Continuity
4.
5.
Close the air bleed.

Injection pump solenoid wire.
Fuel tank cap.
Start the engine and allow it to idle for five minutes.
In s p e c t
Fuel filter for leaks.
IDLE SPEED ADJUSTMENT

CURB IDLE SPEED (Figure 3)
Tool Required: J-26925, Tachometer
1. Set the parking brake and block the drive wheels.
2. Engine must be at normal operating temperature with
the air cleaner on and all accessories turned off.
3. Install J-26925 or equivalent per m anufacturers
instructions.
4. Adjust the low idle speed screw (2) on the fuel injection
pump to obtain the curb idle speed shown on the
FAST IDLE SPEED (Figure 3)

1.
2.
3.
4.
5.
Tool Required: J-26925, Tachometer

Set the parking brake and block the drive wheels.
Engine must be at normal operating temperature with
the air cleaner on and all accessories turned off.
Install J-26925 or equivalent per manufacturers
instructions.
Remove the connector from the fast idle solenoid.
Connect an insulated jumper wire from the positive
battery terminal to the solenoid terminal. This will
energize the solenoid.
the fast idle solenoid.
THROTTLE POSITION SWITCH

ADJUSTMENT (LH6 ENGINE WITH
700 R4 TRANSMISSION)
Tool Required: J-33043-A, Gage Block
1. D is co n n e ct the
th ro ttle p o s itio n sw itch (TPS)
connector.
2. Loosen the mounting screws that hold the TPS.
3. Conect an ohmmeter or test light to the IGN (pink) and
EGR (yellow) terminals of the TPS (figure 4).
4. Insert the proper switch closed gage block between
the gage boss on the injection pump and the wide
open stop screw on the throttle shaft (figure 5).
Refer to the Emission Control Information label
for correct gage block.
5. Rotate the throttle lever and hold the wide open stop
screw against the gage block.
6 . Rotate the TPS until there is continuity between the
terminals.
7. Hold the TPS and tighten the mounting screws to 6
N m (53 in. lbs.).
8 . Return the throttle lever to the idle position and remove
the gage block.

9. Insert the proper switch open gage block and rotate
the throttle lever against the block. There should be no
continuity. If there is continuity, repeat steps 1 through
9.
for correct gage block size.
10. Remove the gage block and ohmmeter.
11. Connect the TPS connector.
A. V a cuu m G age
B. P ig ta il C o n n e c to r
C. C lo c k w is e R o ta tio n
D. To V a cuu m S o u rce
E. W id e O pen S to p Pin
F. J-36142
B-07635
Figure 6VRV/Detent Switch Adjustment
VACUUM REGULATOR VALVE

ADJUSTMENT (LL4 ENGINE WITH
AUTOMATIC TRANSMISSION)
1.
2.
3.
4.
5.
Tool Required:
J-33043-A, Gage Block
J-36142, Switch Gage Tool
Loosen the vacuum regulator valve (VRV) so it is free
to rotate on the pump.
Attach a vacuum source of 67 + 5 kPa (20 inches Hg
1.5 inch Hg) to the bottom vacuum port of the VRV.
Attach a vacuum gage to the top vacuum port (figure
6).
Insert the proper gage block between the gage boss on
the injection pump and the wide open stop screw on
the throttle lever (switch on position) (figure 5).
for correct gage block size.
Rotate the throttle shaft and hold it against the gage
block.
NOTICE: Valve must be set while rotating the

valve body clockwise only.
6 . Slowly rotate the vacuum
7.
8.
9.
10.
regulator valve body

clockwise (facing the valve) until the vacuum gage
reads 38.8 2 kPa (11.5 0.6 inches Hg). Hold the
valve body at this position and tighten the mounting
screws to 6 N m (54 in. lbs.).
Check by allowing the throttle shaft to return to the idle
stop position. Then rotate the throttle shaft back
against the gage block and read the vacuum gage.
The gage should read 38.8 2 kPa (11.5 0.6 inches
Hg). If vacuum is outside of limits, reset the valve.
With the valve vacuum set, confirm the detent switch
point by reading the resistance between the ignition
terminal (pink with black stripe) and the detent terminal
(orange).
Insert J-36142 between the wide open stop pin and the
wide open stop screw on the throttle lever.
Rotate the throttle lever against the tool. There should
be no continuity (infinite resistance).
11. Release the throttle lever and remove the switch gage
tool.
12. Rotate the throttle lever to wide open throttle (the lever
stop screw touching the pump stop pin).
13. Check the switch for continuity. The switch must have
continuity (1 to 0 ohms) before the throttle reaches the
wide open throttle position. If the switch does not meet
these specifications, reset the assembly by returning to
step 1 and repeating the entire procedure.
HOUSING PRESSURE
COLD ADVANCE
The Housing Pressure Cold Advance feature advances
the injection tim in g about fo u r degrees d urin g cold
operation. This provides better cold starts, improved cold
idle, and emission control.
The circuit is actuated by a coolant temperature switch
on the rear of the right cylinder head. The switch is
calibrated to open the circuit at 35C (95F). Below the
s w itc h in g p oint, tim in g is adva nce d by decrea sing
housing pressure from 68.95 kPa (10 psi) to zero. Above
the switching point, the housing pressure is returned to
68.95 kPa (10 psi). The fast idle solenoid is energized by
the same switch.
INJECTION LINE
REPLACEMENT
P y | Clean
All line fittings that will be loosened or removed.

Tool Required: J-29664-1, Protective Covers
1. Battery negative cables.
2. Engine cover (G-Van only).
3. Air cleaner at the valve cover.
4. Crankcase ventilator bracket.
A. L e ft B ank
B. R ig h t B ank
B-08130
Figure 7Fuel Injection Lines
6.
7.
8.
9.
It may be necessary to loosen the vacuum pump

hold down clamp and rotate the pump to gain
access to all intake manifold bolts.
Injection line clips.
Intake manifold.
Install J-29644-1 to the intake ports.
Injection line clips at the loom brackets.
Raise the vehicle (left bank of G-Van only).
Injection lines at the nozzles.
$
7.
8.
9.
10.
Tighten

Crankcase ventilator bracket.
Air cleaner.
Engine cover (G-Van only).
Battery negative cables.
INJECTION PUMP
REPLACEMENT
Cap the lines and nozzles immediately.
10.
Do not bend injection lines.

Injection lines at the pump.
Cap the lines and the pump fittings immediately.
Tag the lines for installation.
-- Install or Connect (Figures 7 and 8)

1. Injection lines at the pump.
Uncap the lines and pump fittings.
Refer to the tags for correct installation.
Raise the vehicle (left bank of G-Van only).
2. Injection lines at the nozzles.
Uncap the lines and nozzles.

Injection line clips at the loom brackets.
Intake manifold.
Remove J-29664-1.
Injection line clips.
R-V TRUCK
Tool Required: J29664-1, Protective Covers
2. Intake manifold.
Refer to 6.2 LITER DIESEL (SEC. 6 A 6 ).
3. Injection lines.
4. Accelerator cable at the injection pump (figure 9).
5. Detent cable (if equipped).
6. Fuel return line at the top of the injection pump.
7. Fuel inlet line from the injection pump.
8. All necessary wires and hoses from the injection pump.
9. Air conditioning hose retainer bracket (if equipped).
10. Oil fill tube (includes CDR valve vent hose).
11. Grommet.
Scribe or paint a mark on the front cover and the
injection pump flange.
Rotate the engine to gain access to the bolts that hold
the driven gear to the injection pump.
I <)
B
E
G
H
12 .
13.
14.
15.
Access is gained through the oil filler neck hole

(figure 10).
Bolts (10).
Nuts (11) (figure 11).
Pump.
Cap all open lines and nozzles.
Gasket (12).
Install or Connect
1. New gasket (12).
2. Injection pump to the front cover.
Align the locating pin on the pump hub (14) with
the slot in the injection pump driven gear (13)
(figure 12).
3. Nuts (11) (figure 11).

Check the timing mark alignment before
fully torquing the nuts.
Drive gear to injection pump bolts ( 10) (figure 11).
Tighten
A.
B.
C.
D.
E.
F.
G.
H.

Grommet.
C yl
C yl
C yl
C yl
C yl
C yl
C yl
C yl
nder
nder
nder
nder
nder
nder
nder
nder
N um ber
N um ber
N um ber
N um ber
N um ber
N um ber
N um ber
N um ber
7
2
6
5
4
3
1
B-08131
10.
B-08133
Figure 8Injection Line Routing

Figure 10Pump Drive Gear Bolts
A. In je c tio n P um p G e ar
B. A lig n m e n t M ark
C. C am G ear
10. B o lt
11. N ut
12. G a sket
14. P um p H ub
-j 2
B-08134
Figure 11Injection Pump Installation

6 . Oil fill tube including the CDR valve vent hose.
7. Air conditioning hose retainer bracket (if equipped).

8 . Fuel feed line at the injection pump.
Tighten
Fitting to 25 N m (20 ft. lbs.).
Fuel return line to the top of the injection pump.
Detent cable (if equipped).
All necessary wires and hoses.
Accelerator cable.
Injection lines.
Intake manifold.
9.
10.
11.
12.
13.
14.
G-VAN
Tool Required: J-29664-1, Protective Covers

2. Engine cover.
3. Intake manifold.
4. Air cleaner inlet hose.
Rotate the snorkel up.
5. Hood latch.
6 . Hood latch cable and move it aside.
7. Windshield washer bottle.
8 . Fan shroud bolts.
10. Rubber hose from the oil fill tube.
11. The oil fill tube nuts.
12. The oil fill tube.
13. The oil fill tube grommet.
14. The drive gear to injection pump bolts (10) (figure 10).
Rotate the engine as necessary.
15. Fuel filter and bracket including the line to the injection
pump.
16. Wire looms from the injection lines.
17. Injection lines from the brackets.
18. The oil pan dipstick tube at the left cylinder head.
19. Electrical connections at the injection pump.
20. Detent cable (if equipped).
21. Accelerator cable.
22. Injection lines.
23. Fuel return line.
Scribe or paint a mark on the front cover and the
injection pump flange.
24. Pump to front cover attaching nuts (11) (figure 11).
25. Injection pump.
Cap all open discharge fittings.
26. Gasket (12).
Install or Connect
1. New gasket.
2. Injection pump to the front cover.
Align the locating pin on the pump hub with the
slot in the injection pump driven gear (figure 12).
3. Nuts (11).
Tighten

Check the timing mark alignment before
fully torquing the nuts.
4. Drive gear to injection pump bolts (10).
Tighten
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Fuel return line.
Injection lines.
Accelerator cable.
Detent cable (if equipped).
Electrical connections at the injection pump.
The oil pan dipstick tube at the left cylinder head.
Injection lines to the brackets.
Wire looms to the injection lines.
Fuel filter and bracket including the line to the injection
pump.
The oil fill tube grommet.
The oil fill tube.
The oil fill tube nuts.
Rubber hose to the oil fill tube.
Upper fan shroud.
Fan shroud bolts.
Windshield washer bottle.
Hood latch cable.
Hood latch.
Air cleaner inlet hose.
Intake manifold.
Engine cover.
INJECTION TIMING
ADJUSTMENT
For the engine to be properly tim ed, the marks on the
top of the engine front cover must be aligned with the
marks on the injection pum p flange (figure 13). The
engine must be off when the tim ing is reset. On Federal
models, align the scribe marks. On California models,
align the half circles.
Adjust
Injection timing.
Loosen the three pump retaining nuts.
Align the mark on the injection pump with the
mark on the front cover.
Tighten
Pump retaining nuts to 40 N m (30 ft. lbs.).
2 . Throttle rod.
MARKING TDC ON THE

FRONT HOUSING
Tool Required: J-33042, Timing Fixture
1. Set the engine so that number 1 cylinder is at TDC
(firing).
2. Install J-33042 in the injection pump location.
Do not use the gasket.

Align the timing mark on the injection
pump flange with the mark on the front
cover.
5. Remaining pump gear attaching bolts.
Rotate the engine to gain access to the bolts.
Tighten
3. The slot in the injection pump gear should be in the

vertical 6 oclock position (figure 14). If not, remove
J-33042 and rotate the engine crankshaft 360 degrees.
The timing marks on the gears will be aligned.
4. Fasten J-33042 to the gear and tighten (figure 15).
5. Install one 10 mm nut to the upper housing stud to hold
the tool flange.
The nut should be finger tight.
6 . Tighten the large bolt (18 mm head) clockwise (looking
at the front of the engine) to 48 N m (35 ft. lbs.).
7. Tighten the 10 mm nut.
8. Check that the crankshaft has not rotated and that the
tools did not bind.
9. Strike the scriber with a mallet to mark TDC on the
front housing.
10. Remove J-33042.
"" Install or Connect

Gasket.
Injection pump.
Nuts (finger tight).
One 8 mm bolt to attach the gear to the pump hub.

Injection pump nuts to 40 N-m (30 ft. lbs.).
B-07637
Figure 15Marking TDC on the Front Housing
INJECTION NOZZLES
Nozzles used in G m odels are shorter than nozzles

used on R-V and P models. Attempts to use the incorrect
nozzle will damage the cylinder heads. When replacing
nozzles, reference should be made to the part number
which is stamped on the side of the nozzle (figure 16).
INJECTION NOZZLE
REPLACEMENT
1.
2.
3.
4.
Tool Required: J-29873, Nozzle Socket

Fuel line clip.
Fuel return hose.
Fuel injection line.
Cap the nozzle and lines.
NOTICE: When removing an injection nozzle,

use J-29873. Remove the nozzle using the 30
mm hex portion (figure 16). Failure to do so will
result in damage to the injection nozzle.
5. Injection nozzle using J-29873.

Tool Required: J-29873, Nozzle Socket
NOTICE: When installing an injection nozzle,
use J-29873. Install the nozzle using the 30 mm
hex portion (figure 16). Failure to do so will
result in damage to the injection nozzle.
1. Injection nozzle using J-29873.
Tighten
Nozzle to 70 N-m (50 ft. lbs.).
Fuel injection line.
Tighten
3. F u e l re tu rn h o s e .
4. Fuel line clip.

INJECTION NOZZLE TESTS

Nozzle testing is comprised of the following checks:
Nozzle opening pressure
Leakage
Chatter
Spray pattern
Each test should be considered independent of the
others (for example, when checking opening pressure, do
not check for leakage).
If all of the above tests are satisfied, the nozzle holder
assembly can be re-used. If any one of the tests is not
satisfied, the complete nozzle holder assem bly must be
replaced. The nozzle holder will then be checked and
repaired at a centralized location.
Test Lines - 6 x 2 x 400 mm (1.5 mm bore).
Test Fluid - per ISO 4113 (Example: Shell V 1399,
Viscosity 1487C or equivalent).
Kinetic Viscosity at 40 - per ISO 3104: 2,45 - 2.75 mm
2/second.
Test oil temperature during test: 20 - 25C (6 8 F 77F).

Refer to the equipment manufacturers instructions for
exact test procedures.
1. Connect the nozzle holder assembly to the test line.
2. Place clear plastic tubes on overflow connections to
prevent leakoff from being confused with actual leak.
3. Close the shutoff valve to the pressure gage.
CAUTION: When testing nozzles, do not place

your hands or arms near the tip of the nozzle.
The high pressure atomized fuel spray from a
nozzle has sufficient penetrating power to
puncture flesh and destroy tissue and may
result in blood poisoning. The nozzle tip should
always be enclosed in a receptacle, preferably
transparent, to contain the spray.
4. Fill and flush the nozzle holder assembly with test oil
by activating the lever briskly and repeatedly. This will
apply test oil to all functionally important areas of the
nozzle and purge it of air.
OPENING PRESSURE TEST

1. O pen
the s h u to ff valve at the p re ssure gage

one-quarter turn.

your hands or arms near the top of the nozzle.
always be enclosed in a receptacle preferably
2. Depress the tester lever slowly. Note at what pressure
the needle of the pressure gage stopped. The
maximum observed pressure is the opening pressure.
Some nozzles may pop while other nozzles may
drip down (this is not leakage).
3. The opening pressure should not fall below the lower
limit of 105 bar (1500 psi) on used nozzles.
4. Replace nozzles which fall below the lower limit.
LEAKAGE TEST
1. Further open the shutoff valve at the pressure gage V2
to 1 V2 turns).
2. Blow-dry the nozzle tip.

3. Depress the lever of the manual test stand slowly until

the gage reads a pressure of 95 bar (1400 psi).
Observe the nozzle tip. A drop may form on the end of
the nozzle but should not drop off within a period of 10
seconds.
4. Replace the nozzle assembly if a drop falls during the
10 seconds.
CHATTER TEST
When testing for chatter, it should be noted that the
sound (chatter) for new and used nozzles may vary. This
is due to carbonized fuel deposits on the pintle and
nozzle tip of used nozzles. With some used nozzles,
chatter is difficult to detect during slow actuation of the
hand lever.
Some nozzles may chatter louder than others. As long
as there is chatter, the nozzle is acceptable.
1. Close the shutoff lever at the pressure gage.

nozzle has su fficien t penetrating power to
2. Depress the lever of the test stand slowly and note
whether chatter noise can be heard.
3. If no chattter is heard, move the lever faster until it
chatters. At fast lever movement, the nozzle may make
a hissing or squealing sound rather than the
normal chatter. This is acceptable.
4. These sounds indicate that the nozzle needle moves
freely and that the nozzle seat, guide, and pintle are
OK.
5. Replace nozzles that do not chatter.
SPRAY PATTERN
This nozzle features a longer nozzle overlap, greater
p in tle to b o d y c le a ra n c e , g re a te r n e e d le to b o d y
clearance, and an internal wave washer between the
nozzle nut and the nozzle. These features make objective
spray pattern testing difficult.
A pop tester will not deliver fuel fast enough for proper
spray pattern analysis. Based on this, this type of nozzle
should not be rejected for spray pattern.
INJECTION PUMP ON-VEHICLE SERVICE
A.
B.
C.
D.
E.
F.
P um p C ove r
H ead A n d R o to r A s s e m b ly
Cam A d v a n c e S cre w
T im in g L in e S id e C over
G u id e S tu d
A d va n ce S crew H o le Plug
B-08139
Figure 18Injection Pump Components Location

Refer to figure 18 for injection pump components loca
tion.
PUMP COVER SEAL AND/OR

GUIDE STUD SEAL
REPLACEMENT
7. Injection pump cover screws.
Clean
Injection pump cover.

Upper portion of the pump.
The guide stud area.
Place several rags in the engine valley to catch
fuel.
4-+ Remove or Disconnect

1.
2.
3.
4.
5.
6.
Tool Required: J-29664, Manifold Cover Set

Negative battery cables.
Air cleaner and intake manifold.
Install J-29664 in the cylinder heads.
Injection pump fuel solenoid wire.
Housing pressure cold advance wire.
Fuel return line.
Top attaching bolt and loosen the lower attaching bolt
on the fast idle solenoid. Move the solenoid aside.
NOTICE: Extreme care must be used to keep

foreign m aterial out o f the pum p when the
cover is off. If any objects are dropped into the
pump, they must be removed before the engine
is started or injection pum p and engine damage
could occur.
8 . Injection pump cover.
9. The guide stud and washer.

Note location of parts prior to removal.
B-08142
Figure 19Metering Valve Spring Position
Figure 20Installing the Injection Pump Cover
Observe the position of the metering valve spring

over the top of the guide stud (figure 19). This
position must be exactly duplicated during
assembly.
10. Pump cover seal from the pump cover.
Install or Connect
1. The guide stud with a new washer.

Make sure that the upper extension of the
metering valve spring rides on top of the guide
studs.
The guide stud to 9.5 N m (85 in. lbs.).

Overtightening the guide stud may strip
the aluminum threads in the housing.
2. New pump cover seal in the pump cover.
3. The pump cover.
The screws should not be in the pump cover.
Position the cover about 6 mm ( 1/4-inch) forward
(toward the shaft end) and about 3 mm (Vs-inch)
above the pump (figure 2 0 ).
Move the cover rearward and downward into
position, being careful not to cut the seal.
Hold throttle in the idle position.
4. The cover screws.
Be careful not to drop or lose the flat washer and
spring washer on each screw.
The flat washer must be against the pump cover.
Tighten

Battery negative cables.
I*
Inspect
Turn the ignition switch to the run position and
touch the pink wire to the solenoid connector. A
clicking noise should be heard as the wire is
connected and disconnected. If this clicking is
not heard, the linkage may be jammed in the
wide open throttle position and the engine MUST
NOT BE STARTED. If clicking is not heard,
6.
7.
8.
9.
10.
remove the cover and ground the solenoid lead

(opposite the hot lead) and connect the pink
wire. With the ignition switch in the run position,
the solenoid in the cover should move the
linkage. If not, the solenoid must be replaced.
Minimum voltage across the terminals must be
12.0. Install the cover and repeat the inspection.
Fuel return line, throttle cable, and the return springs.
Fast idle solenoid.
Idle roughness may be observed due to air in the
pump. Engine idling will allow the air to purge.
It may be necessary to shut the engine
down for several m inutes to allow air
bubbles to rise to the top of the pump.
Intake manifold and air cleaner.
Remover J-29664.
MINIMUM-MAXIMUM
GOVERNOR REPLACEMENT
Tool Required:
J-29664, Manifold Cover Set
Negative battery cables.
Air cleaner and intake manifold.
Fuel Return line.
Fast idle solenoid top attaching bolt.
Loosen the lower bolt, and move the solenoid
aside.
Injection pump cover screws.
JQ* Clean

stud.
Tighten
The guide stud to 9.5 N-m (85 in. lbs.).
3. New pump cover seal in the pump cover.
4. The pump cover.
Position the cover about 6 mm (1/4-inch) forward
above the pump (figure 2 0 ).
Hold throttle in the idle position.
A.
B.
C.
D.
M in - M ax G o ve rn o r A s s e m b ly
M in - M ax G o ve rn o r Sleeve
Seal
T h ro ttle S h a ft
Screw s to 3.7 N-m (33 in. lbs.).

6 . Battery negative cables.
I?
B-08140
Figure 21Injection Pump Cover Removed

the fuel.
foreign m aterial out o f the pum p when the
could occur.
8 . Injection pump cover.

Note the location of parts prior to removal.
assembly.
10. Pump cover seal from the pump cover.
11. Minimum-Maximum governor assembly.
Rotate the throttle shaft and the governor
assembly until the governor clears the housing.
Governor assembly from the throttle shaft.
4- Install or Connect (Figure 21)
1. Minimum-Maximum governor assembly.
Rotate throttle shaft to full throttle.
Place the slotted portion of the governor
assembly onto the throttle shaft slot.
Rotate the throttle shaft with governor assembly
into the housing.
2 . The guide stud with a new washer.
7.
8.
9.
10.
11.
Inspect

wide open position and the engine MUST NOT
BE STARTED. If clicking is not heard, remove
the cover and ground the solenoid lead (opposite
the hot lead) and connect the pink wire. With the
ignition switch in the run position, the solenoid in
the cover should move the linkage. If not, the
solenoid must be replaced. Minimum voltage
across the terminals must be 12.0. Install the
cover and repeat the inspection.
Fast idle solenoid.

down for several m inutes to allow air
Remove J-29664.
THROTTLE SHAFT SEAL

REPLACEMENT
Tools Required:
J-29601, Injection Pump Timing Adapter
J-29664, Manifold Cover Set
1. Negative battery cables.

assembly.
12. Min - max governor assembly (figure 21).
Rotate the assembly up to provide clearance.
If the idle governor spring becomes disengaged
from the throttle block, it must be reinstalled with
the tightly wound coils toward the throttle block.
13. The throttle shaft assembly.
I*
Inspect
Throttle shaft for unusual wear or damage.

Throttle shaft bushings for damage or unusual
wear or leaks.
Remove the pump and send it to the local
Stanadyne dealer if bushing replacement
is necessary.
14. The throttle shaft seals.
Do not attempt to cut the seals, as nicks in the
seal seat will cause leakage.
2. Air cleaner and intake manifold
3. Injection pump fuel solenoid, housing pressure cold
advance wires, and the fuel return line.
4. Throttle rod and the return springs.
Mark the position of the TPS switch or VRV for
installation.
5. Top attaching bolt on the fast idle solenoid. Move the
soleniod aside.
6 . Throttle cable bracket.
7. Throttle shaft advance cam and fiber washer.
Install J-29601 over the throttle shaft with the
slots on the tool engaging the pin (figure 22). Put
the spring clip over the throttle shaft advance
cam and tighten the wing nut. Pull the tool off of
the shaft without loosening the wingnut This
provides proper advance cam alignm ent for
assembly.
Loosen the face cam screw.
1.
2.
3.
4.
5.
D r iv e t h e p in f r o m t h e t h r o t t le s h a f t .
8 . Any burrs from the throttle shaft that may have resulted
from pin removal.

9. Injection pump cover screws.
Clean

fuel.

foreign m aterial out of the pum p when the
could occur.
10. Injection pump cover.
Note location of parts prior to removal.
6.
Tools Required:
J-29601, Injection Pump Timing Adapter
J-33198, Synkut Oil Seal Lubricant
New throttle shaft seals.
Use care not to cut the seal on the sharp edges
of the shaft.
Apply J-33198 or a light coating of clean chassis
grease to the seals.
The throttle shaft to the point where the min - max
governor assembly will slide back onto the shaft.
Throttle shaft and governor into position.
Rotate the min - max governor assem bly
downward (figure 21 ).
New mylar washer, the throttle shaft advance cam, and
a new throttle shaft drive pin (figure 2 2 ).
Do not tighten the cam screw.
J-29601 over the throttle shaft with the pin in the slots
and the spring clip over the advance cam.
A 0.005-inch feeler gage between the white washer on
the throttle shaft and the pump housing (figure 23).
Tighten
Cam screw to 3.1 N m (30 in. lbs.).
Squeeze the throttle shaft.
Secure the screw with Loctite 290 or
equivalent.
Remove J-29601.
7. The guide stud with a new washer.
stud.
Tighten
The guide stud to 9.5 N m (85 in. lbs.).
8 . New pump cover seal in the pump cover.
9. The pump cover.
Figure 23Setting Advance Cam to Housing

Clearance
Position the cover about 6 mm (1/4-inch) forward
above the pump (figure 22 ).
Tighten

11. TPS switch or VRV.
. Battery negative cables.
12
I?
13.
14.
15.
16.
17.
Inspect

wide open throttle position and the engine MUST
NOT BE STARTED. If clicking is not heard,
remove the cover and ground the solenoid lead
(opposite the hot lead) and connect the pink
wire. With the ignition switch in the run position,
the solenoid in the cover should move the
linkage. If not, the solenoid must be replaced.
Minimum voltage across the terminals must be
12.0. Install the cover and repeat the inspection.
Fast idle solenoid.
down for several minutes to allow air
Remove J-29664.
SHUTDOWN AND/OR COLD

ADVANCE SOLENOID
REPLACEMENT
1. Pump cover.
Refer to Pump Cover Seal And/Or Guide Stud
Seal Replacement.
2. Terminal contact nuts.
3. Solenoid.
Note the positions of the insulating washers.

1. Solenoid in the pump cover.
On the shutdown solenoid, make sure that the

linkage is free.
On the cold advance solenoid, make sure that
the plunger is centered so that it will contact the
check ball in the fitting.
2. Insulating washers on the terminal studs (where used).
3. Terminal nuts.
Tighten
4. Pump cover.
Refer to Pump Cover Seal And/Or Guide Stud
Seal Replacement.
I*
Inspect
Solenoid operation prior to installing the pump
cover. Use a 12 V DC power source.

SIDE COVER GASKET
REPLACEMENT
1. The two screws (40).
2. Cover (41).
3. Gasket (42).

1. Gasket.
2. Cover.
3. Screws.
40. S cre w s
41. C over
42. G a sket
Screws to 2 N m (18 in. lbs.)
B-08147
Figure 25Side Housing and Drive Group
INJECTIO N PUMP OFF-VEHICLE SE R V IC E

Refer to Injection Pump R eplacem ent. Off-vehicle
service operations require a leak test after the repair has
been made. Refer to Pressure Testing The Injection
Pump.
ADVANCE PIN HOLE PLUG

SEAL REPLACEMENT
1. Injection pump.
2. Plug (50).
Tap the plug lightly with a hammer to loosen it.
3. Seal (51).

1. New seal.
Lubricate the seal.
2. Plug.
Q
Tighten
Plug to 10 N-m (90 in. lbs.).

Injection pump.
ADVANCE PISTON SEALS

REPLACEMENT
49.
50.
51.
52.
53.
54.
55.
3. Seal (53).
4. Power side advance piston hold plug .(55).
5. Seal (54).
Seal
Seal
P ow er S id e P lug
Figure 26Advance Piston Group
1. Injection pump.
2. Spring side advance piston hold plug (52).
C am A d v a n c e Pin
Plug
Seal
S p rin g S id e P lug

1. New
2. Plug
3. New
seal (54).
Lubricate the seal.
(55).
seal (53).
B-08148

4. Plug (52).
5. injection pump.
ADVANCE PISTON
REPLACEMENT
1.
2.
3.
4.
5.
Injection pump.
Advance piston hold plugs (52 and 55).
Cam advance pin plug (50).
Cam advance pin (49).
Advance piston.

1.
2.
3.
4.
Advance piston.
Cam advance pin (49).
Cam advance pin plug (50) using a new seal (51).
Advance piston hold plugs (52 and 55) using new seals
(54 and 53).
5. Injection pump.
HYDRAULIC HEAD SEAL

REPLACEMENT
1. Injection pump.
2. Throttle shaft and seals.
Refer to Throttle Shaft Seal Replacement.
3. Metering valve (figure 27)
4. Housing vent wire screw assembly (figure 28).
5. Cam advance pin hold plug (50) (figure 26).
6 . Seal from the plug.
7. Cam advance pin (49) (figure 26).
8 . Head locking screws (figure 29).
Locate the pump assembly so the rear of the
pump is sloping down.
9. Head locating screw and seal (figure 30).

10. Hydraulic head assembly using a twisting motion.
11. O-ring seal.
1. New o-ring seal to the hydraulic head.
Lubricate the seal.
2. Hydraulic head assembly into the pump housing.
3. Head locking screws loosely (figure 29).
Lubricate the screws.
4. New seal on the head locating screw.
5. Head locating screw (figure 30).
Turn the pump upside down.
Figure 28 V e nt W ire A s se m b ly
Tighten
Screw to 23 N m (17 ft. lbs.).
6 . The advance pin (49) (figure 26).
7. New seal on the advance pin hole plug.

Lubricate the seal.
8 . The advance pin hold plug.
Tighten
Plug to 10 N m (90 in lbs.).
9. Housing vent wire screw assembly (figure 28).
A. D rive S h a ft S e als
B-08149
Figure 31Drive Shaft Seals
DRIVE SHAFT SEAL

REPLACEMENT
Figure 29Head Locking Screws
10. Metering valve (figure 27).

11. Throttle shaft and seals.
Refer to Throttle Shaft Seal Replacement.
12. Injection pump.
Tool Required: J-29692-B, Holding Fixture

Injection pump.
Fast idle solenoid bracket.
Mount the pump in J-29692-B and tilt it.
The drive shaft from the pump using a rotating motion
(alignment pin at the top).
The shaft is retained by an o-ring.
Make sure that no pieces of the o-ring have
broken off in the pump.
4. The drive shaft seals.
++
Tools Required:
J-29692-B, Holding Fixture
J-29745-A, Shaft Seal Protector
J-33198, Synkut Lubricating Oil
One black seal on the shaft using J-29745-A.
Lubricate the seal protector with J-33198 or
equivalent.
2 . The red seal using J-29745-A.
equivalent.
3. The other black seal using J-29745-A.
equivalent.
New o-ring retaining clip on the shaft.
Drive shaft into the pump.
Make sure the drill points on the drive shaft end
match up with the rotor.
Fast idle solenoid bracket.
Injection pump.
PRESSURE TESTING THE

INJECTION PUMP
Drain all fuel from the pump.
Connect an air line to the pump inlet connection.
Make sure the air supply is clean and dry.
Completely immerse the pump in a bath of clean test
oil.
Seal off the return line fitting.

4. Raise the air pressure in the pump to 137.9 kPa (20
psi). Keep the pump immersed in the oil for 10 minutes
to allow any trapped air to escape.
5. Watch for leaks after the ten minutes. If the pump is not
leaking, reduce the air pressure to 13.8 kPa (2 psi) for
30 seconds. If there is still no leakage, increase the
pressure to 137.9 kPa (20 psi). If there are no leaks, the
pump is ready for use.
SPECIFICATIO NS
Fasteners
Injection Line F ittin g s ................................................
Intake Manifold Bolts...................................................
Injection Pump Mounting N u ts.................................
Injection Pump Drive Gear B o lts ............................
Injection N ozzles.........................................................
Injection Pump Cover S c r e w s .................................
Injection Pump Guide Stud .....................................
Solenoid Terminal N uts..............................................
Side Cover S c re w s .....................................................
Advance Pin Hole P lu g ..............................................
Head Locating S c re w ................................................
Torque
........................
........................
........................
........................
........................
........................
........................
........................
........................
........................
........................
25 N m
40 N m
40 N m
25 N m
70 N m
3.7 N m
9.5 N m
1.2 N m
2 Nm
10 N m
23 N m
2 0 ft. lbs.
30 ft. lbs.
30 ft. lbs.
2 0 ft. lbs.
50 ft. lbs.
33 in. lbs.
85 in. lbs.
12 in. lbs.
18 in. lbs.
90 in. lbs.
17 ft. lbs.
SP E C IA L TOOLS
J-26925
J-36142
J-29601
J-33198
-29664
J-33042
J-29692-B
J-29745-A
1 . T a c h o m e te r
2 . In je c tio n P u m p T im in g A d a p te r
3. P ro te c tiv e C overs
4. H o ld in g F ix tu re
5. S h a ft Seal P ro te c to r
10
J-33043-A
J-29873
6 . N ozzle S o c k e t
7.
8.
9.
10.
T im in g F ix tu re
G age B lo c k
S y n k u t L u b ric a tin g O il
S w itc h G age Tool
B-07634
6D-1
SECTION 6D
EN G IN E ELECTRICAL
CONTENTS
S U B JE C T
Electrical System...............................................
B attery..............................................................
Description....................................................
General Information.......................................
Diagnosis of Battery.........................................
Visual Inspection...........................................
Hydrometer T e s t...........................................
Load T e s t......................................................
Battery On-Vehicle S e rvice.............................
Battery Charging Procedures.......................
Current Drain Test.........................................
Battery Cables...............................................
Battery Replacement.....................................
Charging System...............................................
Description......................................................
Diagnosis of Charging System.........................
Noisy Generator.............................................
Electrical Tests...............................................
SI Charging System.......................................
CS-130 Charging S ystem .............................
Generator On-Vehicle Service.........................
Generator Replacement.................................
Diesel Glow Plug Electrical System..................
Description.....................................................
Diagnosis of Glow Plug Electrical System ----Circuit Check.................................................
Glow Plug Inhibit Switch...............................
Glow Plug System.........................................
Glow Plug A fterstart.....................................
Glow Plug On-Vehicle Service.........................
Cranking System...............................................
Diagnosis of Cranking System.........................
Cranking Circuit.............................................
Starter Motor Noise.......................................
Diagnosis of Starter Motor Noise.....................
Cranking System On-Vehicle Service..............
Maintenance...................................................
Starter M o to r.................................................
Starter Motor Replacement...........................
Engine Block Heaters.......................................
On-Vehicle S ervice.......................................
Ignition System.................................................
Description.....................................................
Distributor......................................................
Engines with T B I...........................................
Spark Plug W ires...........................................
Spark P lu g s ...................................................
Diagnosis of Ignition System...........................
Distributor/Timing System for TBI-Equipped Engines..................................................................
Ingition System for Carbureted Engines___
Diagnosis of Spark Plugs.................................
PAGE
................6D- 2
................6D- 2
................6D- 2
................6D- 3
................6D- 4
................6D- 4
................6D- 4
................6D- 4
................6D- 5
................6D- 5
................6D- 5
................6D- 6
................6D- 6
................6D- 7
................6D- 7
................6D-10
................6D-10
................6D-10
................ 6D-10
............... 6D-12
................6D-14
................6D-14
................6D-15
................6D-15
................6D-16
................6D-16
................6D-16
................6D-19
................6D-19
................6D-19
................6D-19
................6D-19
................6D-22
................6D-22
................6D-24
................6D-27
................6D-27
................6D-27
................6D-27
................6D-27
................6D-28
................6D-28
................6D-28
................6D-33
................6D-33
................6D-33
.................. 6 D -3 3
................6D-35
................6D-35
................6D-36
................6D-36
................6D-36
................6D-39
6D-2 ENGINE ELECTRICAL

t
CONTENTS (Contd.)
SUBJECT
PAGE
Ignition System On-Vehicle S ervice................................................................................................................... 6D-40

Service Precautions...........................................................................................................................................6D-40
Distributor Replacement...................................................................................................................................6D-41
Ignition Timing...................................................................................................................................................6D-41
Spark Plug W ires...............................................................................................................................................6D-42
Spark Plug Wire Replacement......................................................................................................................... 6D-42
Engine Wire Harness............................................................................................................................................ 6D-52
Specifications......................................................................................................................................................6D-77
Special T o o ls ......................................................................................................................................................6D-80
ELEC TRIC A L SY ST E M
Engine electrical system diagnosis includes the battery,
charging system (generator and related wiring), cranking
system (starter and related wiring), ignition system (dis
tributor, spark plugs and wiring) and the glow plug system
(diesel electrical).
Light duty emission vehicles are equipped with an elec
tronic computer comm and control system. These vehicles
have a Check Engine or Service Engine Soon lamp

on the instrum ent panel. Refer to the Fuel and Emissions
Service Manual for a detailed description of the lam ps
operation and use as a diagnostic indicator.
Some vehicles sold in Canada may have variations in
electrical components. Refer to the appropriate Canadian
Service Manual Supplement.
BA T T ER Y
gasses that are produced in the battery to escape. The
special chem ical composition inside the battery reduces
gassing to a very small am ount at normal charging
voltages. Besides reducing gassing, the special chem istry
greatly reduces the possibility of overcharge damage.
Keep the battery in an upright position to prevent
electrolyte leakage. Tipping the battery beyond a 45
degree angle in any direction can allow a small amount of
electrolyte to leak out the vent hole.
Do not exceed this 45 degree angle when carrying or
installing the battery.
Evidence of electrolyte leakage does not always mean
the battery is defective.
RATINGS
Figure 1Sealed Battery with Side Terminals
DESCRIPTION
The battery has three m ajor functions in the electrical
system: first, it provides a source of energy for cranking
the engine; second, it acts as a voltage stabilizer for the
electrical system; and third, it can, for a limited time,
provide energy when the electrical load used exceeds the
output of the generator.
The sealed battery as shown in figure 1 is standard.
Water never needs to be added. There are no filler caps in
the cover. The battery is sealed, except for small vent
holes in the cover. The vents allow what small amount of
Batteries are rated according to their reserve capacity

in minutes and their cold cranking power in amperes.
Both methods involve m easuring the battery term inal
voltage after a specified tim e period and discharge
current.
The reserve capacity is defined as the maximum
length of tim e it is possible to travel at night with m inimum
electrical load and no generator output. Expressed in
minutes, it is the tim e required for a fully charged 12 -volt
battery, at a te m p e ra tu re of 2 7 C (8 0 F), being
discharged at a constant current of 25 amperes, to reach
a term inal voltage of 10.5 volts.
The cold cranking ampere (CCA) test measures the
amperage delivered by the battery at -1 8 C (0 F) for 30
seconds.
Refer to Specifications at the end of this section for
battery ratings.
ENGINE ELECTRICAL 6D-3

battery, normal wearout, or overcharging because of
a problem in the electrical system. C heck the
system and replace the battery.
&
<$>
GENERAL INFORMATION
COMMON CAUSES OF MALFUNCTION
A
2.
3.
4.
A.
B.
C.
Green Dot
Dark
C lear
65% o r Above S tate o f Charge
B elow 65% S tate o f Charge
Low Level E le ctro lyte
B-06941
Figure 2Built-In Hydrometer

BUILT-IN HYDROMETER
T he s e a le d b a tte ry has a s p e c ia l te m p e ra tu re
compensated hydrometer built into the cover to show at a
glance the batterys state-of-charge. The hydrometer has
a green ball within a cage which is attached to a clear
plastic rod. The green ball will float at a predetermined
specific gravity of the electrolyte. When the green ball
floats, it rises within the cage and positions itself under
the rod. Visually a green dot then shows in the center of
the h ydrom eter (figure 2 ). The b uilt-in h ydrom eter
provides a guide for battery testing and charging.
When looking at the hydrometer, make sure that the
battery has a clean top. A lamp may be needed in some
poorly-lit areas.
1. GREEN DOT VISIBLE: The state of charge is 65
percent or more of the full charge.
2. DARK; GREEN DOT NOT VISIBLE: The state of
charge is below 65 percent. Charge the battery until
the green dot appears. (Shake the battery slightly to
make the green dot appear after charging).
3. CLEAR OR LIGHT YELLOW: The fluid level has
dropped below the bottom of the hydrometer. This
can be caused by a broken case, tipping of the
If testing shows the battery to be in good condition but

the battery doesnt perform satisfactorily, check for the
following:
1 . Vehicle accessories left on overnight.
2. Extended slow-speed driving with many accessories
turned on.
3. The v e h ic le e le c tric a l load is m ore th a n the
generator output, particularly with the addition of
aftermarket equipment.
4. Problems in the charging system such as shorts,
slipping fan belt, or worn generator or regulator
parts.
5. Loose or poor battery cable-to-post connections,
previous improper charging of a rundown battery, or
loose hold-downs.
6 . High-resistance connections in the cranking system.
7. Electronic devices draining the battery when the
v e h ic le is p a rke d fo r a long p e rio d of tim e .
Disconnect the negative cable if the vehicle will be
stored for more than 30 days.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, protect it
against freezing by keeping it in a charged condition.
Carrier And Hold-Down

The carrier and hold-down should be clean and free
from corrosion before battery installation.
The carrier should be in a sound mechanical condition
so that it will support the battery securely and keep it
level. Make certain there are no foreign objects in the
carrier before installation.
To prevent the battery from shaking in its carrier, tighten
the hold-down bolts. However, do not tighten the bolts to
where the battery case or cover is placed under a severe
strain.
DIAGNOSIS OF BATTERY
7
7. C ase
8 . 3/8 -in ch 16 U N C N u t
9. 3/8 -in ch 16 U N C B o lt
10. E le c tric a l C o n ta c t
B-09715
Figure 3Testing and Charging Terminal

Adapter
In a diesel-equipped vehicle, check and test each bat
tery separately.
VISUAL INSPECTION
Check for obvious damage such as a cracked or broken
case or cover that could permit loss of electrolyte. If
damaged, replace the battery. Determine the cause of the
damage and correct.
HYDROMETER TEST
GREEN DOT VISIBLE: If the hydrometer has a GREEN
DOT visible the battery is ready for testing. Proceed to
Load Test .
DARK; GREEN DOT NOT VISIBLE: Charge the battery
as o u tlin e d u n d e r the h e a d in g B a tte ry C h a rg in g
Procedure later in this section.
LIGHT OR BRIGHT INDICATOR: Do not charge, test, or
jump start the battery. Replace the battery.
Figure 4Testing and Charging

Using Bolt and Nut
Side Terminal Batteries:
3. If adapters are not available, use a 3/s-inch 16 UNC
bolt and stainless steel nut (figure 4). Finger tighten.
Contact must be made through the lead pads at the
face of the terminals, not through the threads of the
bolt.
Top Terminal Batteries:

4. Attach term inal hex nuts, AC Delco # 7802, or
equivalent (figure 5).
5. Attach the alligator clam ps of the tester or charger
between the term inal nuts and the load pads of the
term inal studs (figure 5).
If the te ste r c la m p s ca n n o t be atta che d
between the nuts and the lead pads of the
terminals, the ampere load for the load test
may change. Refer to Specifications at the
6 . Install a voltmeter and battery load tester to the
adapters.
LOAD TEST
If the battery is in the vehicle, make sure the engine
control switch is off. If there is more than one battery,
check each separately.
1 . Disconnect the battery cables from the terminals.
2 . Install adapter AC-Delco ST 1201 or equivalent
(figure 3).
7. Remove the surface charge from recently charged

batteries by applying a 300-ampere load across the
adapters for 15 seconds.
8 . Do not remove the surface charge from batteries
which have been in storage.

9. Turn the load off and wait 15 seconds for the battery
to recover.

10. Apply the specified load selected from the chart in
Specifications . Observe the battery voltage after
15 seconds with the load connected, then turn off
the load.
11. If the battery voltage does not drop below the
minimum voltage as shown in the Voltage and
Temperature Chart following, the battery is good
and should be returned to service. (The battery
temperature must be estimated by feel and by the
temperature the battery has been exposed to for the
preceeding few hours.) If the battery voltage drops
below the m inim um voltage listed, replace the
battery.
Voltage And Temperature Chart

MINIMUM
VOLTAGE
TEMPERATURE
21 C (70 F & A b o v e )....................................................... 9.6

10 C (50 F).........................................................................9.4
- 1 C (30 F ) ...................................................................... 9.1
-1 0 C (15 F )...................................................................... 8.8
-1 8 C (0 F).........................................................................8.5
Figure 5Testing and Charging

Using Top Terminal Adapter
BATTERY ON-VEHICLE SERVICE

BATTERY CHARGING
PROCEDURES
The following basic rules apply to any sealed battery
charging situation:
1. Do not charge a battery if the hydrometer is clear or
light yellow replace the battery.
2. C harge rates betw een 3 and 50 am peres are
satisfactory as long as spewing of electrolyte does
not occur or the battery does not feel over 52 C,
(125 F). If spewing occurs or temperature exceeds
5 2 C (125 F), the charging rate must be reduced
or temporarily halted to permit cooling.
Estimate battery temperature by touching or feeling
the battery case.
3. The battery is sufficiently charged when the green
dot in the built-in hydrometer is visible. No further
charging is required. Shake or tilt the batter at
h o u rly in te rv a ls d u rin g c h a rg in g to m ix th e
electrolyte and see if the green dot appears.
4. Battery charging consists of a charge current in
amperes for a period of time in hours. Thus a
25-ampere charging rate for 2 hours would be 50
ampere-hour charge to the battery. In most cases,
batteries whose load test values are less than 2 0 0
amperes will have the green dot visible after at least
a 50 ampere-hour charge. Most batteries whose
load test values are greater than 2 0 0 amperes will
have the green dot visible after at least a 75
ampere-hour charge. In the event that the green dot
does not appear after this amount of charging,
c o n tin u e c h a rg in g fo r a n o th e r 50 o r 75
ampere-hours. If the green dot still does not appear,
replace the battery.
5. The time required for a charge will vary according
to:
a. Size of battery Example: A discharged

large heavy-duty battery requires more than
twice the recharging as a discharged small
passenger car battery.
b. Temperature Example: A longer time will be
needed to charge any battery at -1 8 C (0 F)
than at 27 C (80 F). When a fast charger is
connected to a cold battery, the cu rre n t
accepted by the battery will be very low at first;
then, as the battery warms, it will accept a
higher rate.
c. State-of-charge Example: A discharged
battery requires more than twice as much
c h a rg e as a o n e -h a lf-c h a rg e d b a tte ry .
Because the electrolyte is nearly pure water
and therefore a poor conductor, the current
accepted is low at first. Later, as the charging
current causes the electrolyte acid content to
increase, the charging current will likewise
increase.
d. C harger C apacity Exam ple: A charger
which can supply only 5 amperes will require a
much longer period of charging than a charger
that can supply 30 amperes or more.
CURRENT DRAIN TEST

If a battery needs recharging and no cause is evident,
check the vehicle for excessive current drain.
Negative battery cable (both negative cables on
diesels).

CAUTION: To prevent possible personal injury
from a moving vehicle or operating engine do
the following before performing the checks:
1. Engage the parking brakes and block the
wheels.
2. Place the manual transm ission in the
n e u tra l p o s itio n o r th e a u to m a tic
transmission in park.
3. On gas engines disconnect the battery
feed at the distributor. On diesel engines
disconnect the battery feed at the engine
shutoff (ESO) solenoid.
1 . Check the voltage drop between ground (negative
11 . Positive Battery Cable C onnected

12 . B a tte ry (D is c o n n e c t N e g a tiv e C ab le
13.
14.
15.
16.
From O ther B attery On Diesel Vehicles)

M u ltim e te r J-34029-A Equivalent Set On
DC, MA and 2000 Scale
M eter Test Leads
End of Negative B attery Cable
Jum per W ires
B-07712
Figure 6Battery Drain Test Circuit

2.
4.
6.
7.
Tool Required:
J-34029-A Multimeter.
B attery side te rm in a l a dapter in the negative
terminal or nut and bolt as described earlier in this
section.
A 3/s-inch 16 UNC nut on the negative battery cable
terminal attaching screw.
Clip of a jum per wire to the negative battery terminal
adapter (figure 6 ).
Clip at the other end of the jum per wire to digital
multim eter J-34029-A or equivalent.
Clip from the second jum per wire to the end of the
negative battery cable.
Clip at the other end of the wire to the multimeter.
Set the m ultim eter on the DC, MA and 2000
scale.
Take the reading w ith the engine control
switch and all accessories off.
If current draw is more than 50 milliamps, check the
system for causes such as a shorted wire or a
com partm ent lamp that does not shut off when it
should.
BATTERY CABLES
E x c e s s iv e re s is ta n c e c a u s e d by p o o r te rm in a l
connections and partial short circuits through worn cable
insulation will result in an abnormal voltage drop in the
starter cable. Low voltage at the starter will prevent
normal starter operation and cause hard starting.
battery terminal) and the vehicle frame. Place one

prod of the test voltmeter on the grounded battery
post (not on the cable clam p) and the other on the
frame. Operate the starter and note the voltage
reading.
2 . Check the voltage drop between the positive battery
term inal and starter te rm ina l stud w ith starter

operating.
3. Check the voltage drop between the starter housing
and frame with the starter operating.
4. If the voltage drop in any of the above is more than
1.0 volt, there is excessive resistance in the circuit.
To e lim in a te resistance, the c a b le s sh ou ld be
disconnected and connections cleaned. If cables
are frayed or the clam ps corroded, the cables
should be replaced. When selecting new cables, be
sure they are at least as large as the ones being
replaced.
BATTERY
REPLACEMENT
When handling a battery, observe the following safety
precautions.
1. Hydrogen gas is produced by the battery. A flame or
spark near the battery may cause the gas to ignite.
2. B attery flu id is hig hly acidic. Avoid sp illin g on
clothing or skin. Any spilled electrolyte should be
flushed with large quantities of water and cleaned
immediately.
1. N e g a tiv e
term inal.
c a b le
fro m
th e
n e g a tiv e
b a tte r y
2. Positive cable from the positive battery term inal.

3. B attery hold-dow n clam p.
4. Battery.
L * Inspect
1. B attery for dam age.
2. C ables and connectors.
3. C arrie r for dam age or fo re ign objects.
If damage is noted, find and correct the cause.
Install or Connect
1. B attery into cleaned carrier.
2. H old-dow n retainer or top bar, as e quipped.

Tighten
Tighten
1. R etainer to 17 N m (13 ft. lbs.).

2. Top bar to 3.5 N-m (30 in. lbs.) on batteries
w ith side term inals.
3. Top bar to 6.8 N-m (60 in. lbs.) on batteries
w ith top term inals.
3. Battery terminals.
Top te rm in a ls to 17 N-m (13 ft. lbs.).

Side te rm in a ls to 15 N-m (11 ft. lbs.
4. Positive cable to the positive terminal.
5. Negative cable to the negative terminal.
CHARGING SYSTEM
54
51.
52.
53.
54.
BAT Term inal

N o. 1 T erm inal
N o. 2 Term inal
F ie ld G ro u n d H o le
F-00013
51.
52.
53.
54.
BAT T erm inal

No. 1 T erm inal
No. 2 T erm inal
F ie ld G ro u n d H o le
F-02518
Figure 712-SI Series 100 Generator
Figure 817-SI Series 100 Generator
DESCRIPTION
The generator rotor bearings contain enough grease to

eliminate the need for periodic lubrication. Two. brushes
carry current through the two slip rings to the field coil
mounted on the rotor, and under normal conditions will
provide long periods of attention-free service.
The charging system consists of the battery, the

g en erator, th e regulator, and th e ch a rg in g system
indicator lamp circuitry. The generator supplies electrical
power for charging the battery and operating accessories.
Two types of generators are used on these vehicles, the
SI generator with an external 2 -terminal connector on the
re g ula tor, and the CS g e n e ra to r w ith an e x te rn a l
4-terminal connector on the regulator. The diagnostic
tests for these generators are different.
12-SI 100 AND 17-SI 100 GENERATORS

(Figures 7, 8 and 9)
These generators are of the Systems Integral series
(generator with built-in regulator).
The solid state regulator components are enclosed into
a solid mold, and this unit, along with the brush holder
assembly, is attached to the slip ring end frame. The
regulator voltage setting cannot be adjusted.
The stator w indings are assembled on the inside of a

laminated core that forms part of the generator frame.
T he 12-SI has a Y s ta to r and the 17-SI has a
delta-wound stator. A rectifier bridge connected to the
stator w indings contains six diodes, and electrically
changes the stator AC voltages to a DC voltage which
appears at the generator output (BAT) terminal. Generator
field current is supplied thorugh a diode trio which also is
c o n n e c te d to th e s ta to r w in d in g s . A c a p a c ito r or
condenser, m ounted in the end frame, protects the
rectifier bridge and diode trio from high voltages, and
suppresses radio noise.
No periodic adjustments or maintenance of any kind is
required on the entire generator assembly.

to the field coil, then through the wire at term inal number
1 to the charge indicator lamp. The lamp goes out since
approximately the same voltage is present at both sides
of the lamp. On vehicles with gages a voltmeter indicates
voltage.
CS-130 GENERATORS (Figures 10, 11 and 12)
CIRCUIT OPERATION
When the engine control switch is turned to Run or
S tart , the switch closes and current from the battery
flows through the charging system indicator lamp, the
number 1 term inal, the regulator, ground, and back to the
battery. Current also flows through the generator field coil
and back to the battery. The charge indicator lamp then
turns on.
W ith the generator o perating, direct cu rren t (DC)
voltage is applied to the battery through the BAT
terminal. Some of the output flows through the diode trio
51. BAT T erm in al

55. T e rm in a ls P, L, I, S
Figure 10CS-130 Generator
F-02516
These generators feature a high ampere output per

pound of weight. The CS stands for charging system and
130 is the measurement in m illim eters of the outside
diameter of the stator laminations.
This generator with integral regulator does not have a
diode trio. The delta stator, rectifier bridge, and rotor with
slip rings and brushes are electrically sim ilar to other
generators. A conventional fan and pulley are used, and
an internal fan cools the slip rings, end frame, rectifier
bridge and regulator.
The charge indicator lights when the engine control
switch is closed, and goes out when the engine is
running. If the charge indicator is on with the engine
running, a charging system problem is indicated. The
indicator will glow at full brilliance, not half lit, if any
charging problem occurs or if the system voltage is too
high or too low.
The regulator voltage setting varies with temperature,
and limits system voltage by controlling rotor field current.
It sw itches rotor field current on and off at a fixed
frequency of about 400 cycles per second. By varying the
on-off time, correct average field current for proper system
voltage control is obtained. At high speeds, the on-time
may be 10 percent and the off-time 90 percent. At low
speeds, with high electrical loads, on-off tim e may be 90
percent and 10 percent respectively.
The regulator has four terminals, P, L, I, and S
(figure 12). The use of the P, L , and S term inals is
optional. The P term inal is connected to the stator, and
may be wired to a tachometer or other device. The S
term inal may be wired to the battery to sense voltage to
be controlled. The L and I term inals serve to turn on
the regulator and allow field current to flow when the
switch is closed. The I term inal may be connected
directly to the switch, or through a resistor. Both are
illustrated. The I circuit may be used with or w ithout the
L circuit; that is, with or w ithout anything connected to
the L circuit. Refer to the Light Duty Truck W iring
Diagrams for specific application.
The generator is not serviceable, and no periodic
maintenance is required.
57.
58.
60.
64.
67.
Rotor
Stator
R ectifie r Bridge
R egulator
Double Sealed
Ball Bearing
68. Terminals
69. Internal Fan
60
69
F-01361
Figure 11CS Series Generator
-AAA,----------
-9-
-i
zA
<>
i i
-w-
i_______
___________________j
rh
I________________________ _
F-02515
Figure 12CS Generator Schematic
DIAGNOSIS OF CHARGING SYSTEM

NOISY GENERATOR
Noise from a generator may be caused by a loose drive
pulley, loose mounting bolts, worn or dirty bearings, worn
diode or stator. If the pulley and mounting bolts are snug
and the noise continues, remove the generator for
inspection and repair. Refer to Generator Replacem ent
ELECTRICAL TESTS
Before performing the diagnosis procedures on the
vehicle, be certain that the system wiring is good and the
generator belt is not slipping. Also, the battery must be
fully charged for a valid test of the charging system.
NO TICE: To a vo id dam age to the vehicle
e le c tr ic a l s y s te m , o b s e rv e the fo llo w in g
precautions:
Do not polarize the generator.
Do not short across or ground any o f the
terminals in the charging circuit except as
specifically instructed herein.
NEVER o p era te the g en e rato r with the
output terminal open-circuited.
Make sure the generator and battery have
the same ground polarity.
When c on nectin g a charger or booster
battery to the vehicle battery, con nect
n e g a tiv e to n e g a tiv e a n d p o s itiv e to
positive.
Trouble in the charging system will show up as one or
more of the following conditions:
1. On vehicles w ithout gages, unusual operation of the
charging indicator lamp.
2. An u n d e rc h a rg e d b a tte ry, in d ic a te d
cranking or a dark battery hydrometer.
by slow
3. An overcharged battery, indicated by spewing of

electrolyte from the vents.
SI CHARGING SYSTEM
CHARGING SYSTEM INDICATOR
LAMP OPERATION
Check the indicator lamp for normal operation in the
C ha rg ing System D ia g n o s is , (figure 13). If lam p
operation is normal, proceed to Undercharged Battery .
UNDERCHARGED BATTERY
Slow cranking or a dark battery hydrometer can be
caused by one or more of the following conditions even
though the indicator lamp may be operating normally. The
following procedures also apply to vehicles equipped with
a voltmeter.
1 . Check that the
undercharged condition has not

been caused by accessories having been left on for
extended periods.
2. Check the drive belt for proper tension. Refer to

E N G IN E C O O L IN G
(SEC . 6 B) fo r b e lt
specifications.
3. If you suspenct the battery is bad, do a load test.
Refer to Battery earlier in this section.
4. Inspect the wiring for cracks or breaks. Check all
c irc u it co nn ectio ns, ca ble clam ps and b attery
term inals for tightness and cleanliness.
5. With the engine control switch on and all wiring
harness leads connected, use a voltmeter for the
following checks:
+ 4- Install or Connect (Figures 7 and 8)
1. V o ltm e te r fro m th e g e n e r a to r b a tte r y

te rm ina l to ground.
Should read 12 volts.
2. Voltm eter from the num ber 1 term inal to
ground.
Should read one volt or more.
3. Voltm eter from the num ber 2 te rm ina l to
ground.
Should read 12 volts.
A zero reading on any of the above indicates an open
between the voltmeter connection and the battery. If
checks 1 through 5 are normal perform the generator
output test.
OVERCHARGED BATTERY
If the battery feels hot, is spewing electrolyte, or lamps
seem too b rig h t w hen tu rn e d on, an o v e rch a rg e d
condition may exist.
To check the voltage, install a voltmeter across the
battery. Run the engine at m oderate speed with all
accessories off. If the voltage reads 15.5 or more, remove
the generator for repair.
GENERATOR OUTPUT TEST (Figure 14)

1. Disconnect the battery ground cable.
2. Connect an ammeter in the circuit at the battery
terminal of the generator.
3. Reconnect battery ground cable.
4. Turn on the radio, w indshield wipers, headlamps
(high beam) and blower motor high speed.
5. Connect a carbon pile across the battery.
6 . Run the engine at moderate speed (about 2,000
rpm) and adjust the carbon pile to obtain maximum
current output.
7. If the ampere output is within 10 amperes of the
rated ouput as stamped on the generator frame, the
generator is probably all right.
8 . If the vehicle is equipped with a charging system
indicator lamp, and the lamp remains on while the
engine runs, and ampere output is normal, remove
the generator for repair. Check the diode trio and
rectifier bridge.
9. If the ampere output is not within 10 percent of the
rated ouput in amperes, see if the test hole is
accessible (figure 15). If it is not accessible go to
step 14.
10. Ground the field winding by inserting a screwdriver
into the test hole.
CHARGING SYSTEM INDICATOR LAMP OPERATION

E ngine R unning
E n g in e C o n tro l
S w itc h ON
TEST NO. 1
Lamp O ff
NORMAL
See Test 2
Lam p On
NORM AL
See Test 3
La m p O n
C o n n e ct v o ltm e te r to BAT.
te rm in a l on g e n e ra to r and
c h a s s is gro un d. Turn
ig n itio n key on.
Figure 13Charging System
Battery voltage
Engine S to p p e d
E n g in e C o n tr o l
S w itc h O N
TEST NO. 2
C heck 10 amp.
G AG ES
TR AN S. fuse
in fuse block
C h eck drive b e lt and

w irin g c o n n e c tio n s at
g e n e ra to r and b a tte ry
cables.
D is c o n n e c t No. 1 and No. 2 c o n n e c to r

at generator. C o n n e c t vo ltm e te r from
No. 1 c o n n e c to r to ch a ssis ground.
A p p ro x im a te ly
2 to 4 v o lts
Zero volta ge
R epair open c irc u it in No. 1 w ire

fro m c o n n e c to r to e n g in e c o n tro l
* lf b a tte ry is fu lly charged, use the

s ta rte r to p a rtia lly d isch a rg e it before
re co rd in g m a xim u m cu rre n t o u tp u t.
|L a m p O f?
D is c o n n e c t b a tte ry g ro u n d strap.
D is c o n n e c t w ire fro m BAT.
te rm in a l on generator.
C o n n e c t a m m e te r b la ck lead to
BAT. te rm in a l w ire s and red
lead to BAT. te rm in a l.
C o n n e ct b a tte ry gro u n d strap.
T urn o n a ll a c c e s s o rie s , la m p s o n
h igh beam , and b lo w e r on h igh speed.
Run e n g in e as req uire d to o b ta in
m a xim u m c u rre n t o u tp u t and record
a m m e te r re a d in g .*
If th e in d ic a to r la m p o p e ra tio n
is norm al fo r all three te sts,
refer to SI g e n e ra to r d ia g n o s is
D is c o n n e c t No. 1 and 2
c o n n e c to r at ge ne rator.
C h eck 10 amp.
GAGES
T R A N S . fu se
in fu se b lo c k
{L a m p O ff
Lam p On
Lam p On
C h eck b a tte ry c o n n e c tio n s and battery

c o n d itio n .
1. L a m p b u rn e d o u t.
2. O pen in No. 1 w ire from
g e n e r a to r to e n g in e c o n tr o l
s w itc h .
1. C o n n e c t No. 1 and No. 2
c o n n e c to r to generator.
2. In se rt s c re w d riv e r in to
te s t h o le to gro u n d ro to r
w in d in g .
Lam p On
| L a m p O fT
I
R e p la c e r e g u la to r
R epair sh o rt betw een

No. 1 and 2
w ire s in harness.
R e p la c e r e c t if ie r
b r id g e in g e n e r a to r
SWITCH
ENGINE
LAM P
OFF
ON
ON
STOPPED
STOPPED
R U N N IN G
O FF
ON
O FF
N O R M A L LA M P O P E R A T IO N
O u tp u t w ith in 10 am ps of rated o u t
put s ta m p e d on g e ne rator fram e.
CO
CO
R eplace re g u la to r
O u tp u t NOT w ith in 10 am ps o f rated

o u tp u t sta m p e d on g e n e ra to r fram e.
In s e rt s c re w d riv e r in to te st hole.
End o f s c re w d riv e r m u st to u c h ta b and sid e
o f s c re w d riv e r g ro un d a g a in st end fram e.
Run e n g in e as be fore and re ch e ck o u tp u t.
O u tp u t NOT w ith in 10 am ps o f rated
o u tp u t s ta m p e d on g e n e ra to r fram e.
Make sure No. 1 w ire

c o n n e c to r is m aking
good c o n ta c t on te rm in a l.
D isa sse m b le g e n e ra to r
and ch e c k brushes, s lip
rin g s and ro to r w in d in g
fo r open.
Rem ove generator. R efer to

g e n e r a to r d is a s s e m b ly .
6D-11
CD
L a m p O ff]
O u tp u t w ith in 10 am ps o f rated o u t
p ut sta m p e d on ge n e ra to r fram e.
NORMAL
Lam p On
ENGINE ELECTRICAL
Diagnosis
s w itc h .
R e pa ir open c irc u it betw een

BAT te rm in a l on g e n e ra to r
and ju n c tio n b lo c k o r battery.
Install No. 1 and 2 co n n e cto r.
I
L a m p O ff
NORM AL
D is c o n n e c t No. 1 and 2 c o n n e c to r
at generator. G roun d No. 1 w ire.
Do NOT gro u n d No. 2 w ire.
Z e ro v o lta g e
Lam p On
DIM
E n g in e C o n tr o l
S w itc h O F F
TEST NO. 3
6 6 . B a tte ry
54. F ie ld G ro u n d
73. Tab
A. In s e rt screw driver, g ro u n d ta b to end fram e.
70. G e n e ra to r
71. C arbo n Pile
72. A m m e te r
F-00010
Figure 14Connections for Generator Output Test

NOTICE: The tab is within 19 mm (3M inch) of
th e c a s tin g s u r fa c e . Do n o t fo rc e th e
screwdriver deeper than 25 mm (1 inch) into the
end frame or the generator may be damaged.
11. Run the engine at moderate speed and adjust the
carbon pile to get maximum current ouput.
12. If the output is within 10 amperes of the rated ouput,
remove the generator for repair. Refer to the Light
Duty Truck Unit Repair Manual to check the field
winding and regulator.
13. If the output is not within 10 amperes of rated
output, remove the generator and check the field
winding, diode trio, rectifier bridge and stator.
14. If the test hole is not accessible, rem ove the
generator for repair.
GENERATOR DIAGNOSTIC
TESTER INDICATIONS
If a tester is available, check the generator following the
tester m anufacturers instructions. It will indicate about 98
percent of the charging system problems.
F-00011
Figure 15Generator Field Ground Tab

TRANSISTORIZED VOLTAGE
REGULATOR TEST
Connect a fast charger and a voltmeter to the battery as
shown in figure 16. With the engine control switch on
run and the engine off, slowly increase the charge rate.
The charging system indicator lamp (on vehicles without
gages) will dim at the voltage regulator setting. The
setting should be at a minimum of 13.5 volts and a
maximum of 16.0 volts.
This test works if the rotor circuit is good, even if the
stator, rectifier bridge or diode trio is bad.
CS-130 CHARGING SYSTEM

CIRCUIT DIAGNOSIS
Trouble in the charging system will show up as one or
more of the following conditions:
Abnormal indicator lamp operation.
An undercharged battery as evidenced by slow
cranking or dark hydrometer.
An overcharged battery as evidenced by excessive
spewing of electrolyte from the vents.

A basic wiring diagram for the charging system is
shown in fig ure 12. W hen the system is operating
normally, the indicator lamp (on vehicles so equipped) will
come on when the engine control switch is turned on and
go out when the engine starts. If the lamp operates
abnormally, or if an undercharged or overcharged battery
condition occurs, the following procedure may be used to
d ia gn ose the c h a rg in g system . R em em ber th a t an
undercharged battery is often caused by accessories
being left on overnight, or by a switch stuck closed which
allows a lamp, such as a trunk or glove box lamp, to stay
on.
This generator does not have a test hole.
DIAGNOSTIC TEST FOR CS-130

1. Check belt for wear and tension. Refer to ENGINE
COOLING (SEC. 6 B) for belt tension. Check wiring.
2. Go to Step 5 for vehicles without a charge indicator
lamp.
3. With the engine control switch on and the engine
stopped, the lamp should be on. If not, detach the
wiring harness at the generator and ground the L
terminal lead.
If the lamp lights, replace the generator.
74. Fast Charger

75. V oltm eter
66. Battery
F-00012
Figure 16On-Vehicie Regulator Test
If the lamp does not light, locate the open

circuit between the grounding lead and the
engine control switch. The lamp may be open.
4. W ith the switch on, and the engine running at
moderate speed, the lamp should be off. If not,
detach the wiring harness at the generator.
If the lamp goes out, replace the generator.
If the lamp stays on, check for a grounded L
term inal wire in the harness.
5. If the battery is undercharged or overcharged:
Detach the wiring harness connector from the
generator.
With the switch on the engine not running,
connect a voltmeter from ground to the L
terminal in the wiring harness, and to the I
term inal, if used. The wiring harness may
connect to either I or to both.
A zero reading ind icate s an open c irc u it
between the term inal and the battery. Correct
as required.
C o n n e c t th e h a rn e s s c o n n e c to r to th e
generator and run the engine at moderate
speed with accessories off.
Measure the voltage across the battery. If
above 16 volts, replace the generator.
66.
70.
71.
72.
75.
77.
A.
Battery
Generator
Carbon Pile
A m m eter
V oltm eter
R esistor
C onnect R esistor to L Terminal
Connect an ammeter at the generator output

terminal, turn on the accessories and load the
battery with a carbon pile to obtain maximum
amperage. M aintain voltage at 13 volts or
above.
F-02514
Figure 17Connections for Generator Output Test
If the output is within 15 amperes of the

rated output, the generator is OK. (Refer
to Specifications at the end of this
section.)
If the output is not within 15 amperes of
the rated output, replace the generator.

GENEATOR BENCH CHECK
1 . Make connections as shown in figure 17, except
leave the carbon pile disconnected. The ground

polarity of the generator and battery must be the
same. The battery must be fully charged. Use a 30
to 500 ohm resistor between the battery and the L
terminal.
2. Slowly increase generator speed and observe the
voltage.
3. If the voltage is uncontrolled and increases above

16 volts, the rotor field is shorted, the regulator is not
working properly, or both. A shorted rotor field coil
can cause problems in the regulator.
4. If the voltage is below 16 volts, increase speed and
adjust the carbon pile to obtain maximum amperage
output. Maintain the voltage above 13 volts.
5. If the output is within 15 amperes of the rated
output, the generator is good.
6 . If the output is not within 15 amperes of the rated
output, replace the generator.
GENERATOR ON-VEHICLE SERVICE

GENERATOR REPLACEMENT
The removal and installation instructions serve only as
a guide. Additional operations may be required on some
vehicles to remove other equipm ent to gain access to the
generator, drive belts and brackets.
CAUTION: Failure to observe Step 1 in this

procedure may result in an injury from the hot
battery lead at the generator.
+2 Remove or Disconnect
1. N egative battery cable at the battery.
2 . Term inal plug and battery lead from the back of
the generator.
Loosen the upper m ou ntin g/ad ju stin g bolt on the
generator m ounting.
Loosen the belt te nsio ne r (serpentine belt only).
3. Drive belt.
4. Lower m ounting bolt.
U pper m ounting bolt.

Generator.
Install or Connect
G enerator to the top bracket w ith the bolt.
Do not tighten.
Lower mounting bolt to the bracket.
Generator drive belt.
Low er
m o u n tin g
b o lt.
R e fe r
to
S p e c ific a tio n s at th e end of this section.
D rive b elt. R efer to E N G IN E C O O L IN G
(SEC. 6 B) for belt specificatio ns.
U pper generator m ou ntin g bolt. R efer to
S p e cifica tio n s at th e end of th is section.
5. Terminal plug and battery lead to the back of the
generator.
6 . Negative battery cable to the battery.
Refer to the Light Duty Truck Unit Repair Manual for
off-vehicle service.
DIESEL GLOW PLUG ELECTRICAL SYSTEM
630.
640.
641.
642.
643.
G low Plug
Fuel In je c to r
C ylinder Head
Pre C o m b u stio n C ham ber
Heated Sheath
F-00229
F-00228
Figure 18Diesel Engine Glow Plug Location
DESCRIPTION
In the diesel engine, air alone is compressed in the
cylinder; then after the air has been compressed a charge
of fuel is sprayed into the cylinder and ignition occurs due
to the heat of compression. Eight glow plugs are used to
preheat the chamber as an aid to starting (figure 18).
T h e d ie s e l g lo w p lu g s y s te m c o n s is ts o f an
intergral-electronic co ntrol/g low plug relay assem bly,
6 -volt glow plugs, a glow plug inhibit temperature switch
and a GLOW PLUGS lamp.
Figure 19Glow Plug Controller

ELECTRONIC CONTROLLER/GLOW PLUG
RELAY ASSEMBLY (Figures 19 and 20)
The assembly contains the circuitry which monitors and
controls glow plug relay operation. Information is received
at pins B and C which is used by the controller to
determ ine glow plug ope ra ting requirem ents. Pin B
senses voltage at the starting motor solenoid. Pin C
senses glow plug voltage through the glow plug inhibit
switch which is wired in series with the glow plug voltage
sense lead to the glow plugs. The controller is mounted at
the rear of the left cylinder head on two 10 mm studs.
GLOW PLUG INHIBIT SWITCH

GLOW PLUGS
These are 6 -volt heaters (operated at 12 volts) that turn
on when the engine control switch is turned to the run
position prior to starting the engine. They remain pulsing
a short time after starting, then autom atically turn off.
The switch is temperature controlled and opens above

51.5 C (125 F) to prevent glow plug operation above this
temperature. It is mounted at the rear of the right cylinder
head on the P truck and G van, and in the water crossover
near the front of the engine on the RV truck.
INSTRUMENTATION
CIRCUIT OPERATION
V e h ic le s w ith th e d ie s e l e n g in e have s p e c ia l
instrum entation indicators to p erm it the operator to
properly apply the starting procedure. A GLOW PLUGS
lamp on the instrument panel provides this information on
engine starting conditions.
Vehicles equipped with diesel engines have a WATER
IN FUEL lamp and "LOW COOLANT lamp. Refer to the
engine fuel and engine cooling sections for information on
these systems.
A normal functioning system operates as follows:

A. K ey on - E n g in e n o t ru n n in g a n d a t room
temperature.
1. Glow plugs ON for 4 to 6 seconds, then OFF
for about 4.5 seconds.
2. Then cycle; ON for about 1.5 seconds, OFF for
about 4.5 seconds, and continue to cycle 1.5
ON/4.5 OFF, for a total duration (including the
initial 4 to 6 seconds) of about 20 seconds.
639
626.
627.
628.
629.
630.
631.
632.
633.
634.
635.
636.
637.
B a tte ry Feed
5/ie -ln c h O u te r D ia m e te r S tu d s
G lo w Plug C o n tro lle r

G lo w P lug Feed
G lo w P lu g s (6 Volt)
G lo w P lu g s Lam p
G lo w P lug In h ib it Tem perature S w itc h
S ta rte r S o le n o id
E n gin e C ra n k in g S ense In p u t (Purple)
G lo w P lug V o lta g e S ense In p u t (Yellow o r Blue)
E n gin e C o n tro l (Pink)
G rou nd (B lack)
630
638. E n gin e C o n tro l S w itc h

639. B a tte ry
F-02513
Figure 20Electronic Glow Plug System

B. If the engine is cranked during or after the above
sequence, the glow plugs will cycle ON/OFF for a
total duration of 25 seconds after the engine control
switch is returned from the crank position, whether
the engine starts or not. The engine does not have
to be running to terminate the glow plug cycling.
All the tim es shown above are approximate because

they vary with initial engine temperature. The initial ON
time and cycling ON/OFF tim es vary also with system
voltage and/or temperature. Lower temperatures cause
longer duration of cycling.
DIAGNOSIS OF GLOW PLUG ELECTRICAL SYSTEM

CIRCUIT CHECK
If the system does not operate as described, check the
following:
I?
5. Temperature switch connector at top rear right

cylinder head on the P and G truck, and in the water
crossover near the front of the engine on the RV
truck.
6 . GLOW PLUG lamp on instrum ent panel for tight
Inspect
connection and operation.
1. All connectors.
GLOW PLUG
INHIBIT SWITCH
2. Engine harness ground connection to the engine.
Tighten
3. Four-wire connector at controller. It must be fully

seated and latched.
4. Both controller copper stud upper nuts.
Check the temperature-controlled switch to make sure it

is c lo s e d at low te m p e ra tu re s and open at hig h
temperatures.
1. Remove the connector from the inhibit switch when
the engine temperature is below 38C (100F).
2 . Set th e
Tighten
Nuts to 5 N-m (48 in. lbs.)
Do not tighten lower nuts.
o h m m e te r on a low ran ge or use a

self-powered test lamp.
3. Test across the terminals.

4. The switch should be closed (test lamp on or a
reading of less than 0.1 ohm on the meter).
G-VAN
50 MIN.
CONNECT AN AMMETER IN SERIES (INDUCTION TYPE METER MAY ALSO BE USED)*

WITH RED OR ORANGE WIRE LEADING FROM THE TOP OF THE CONTROLLER TO THE
LEFT BANK OF GLOW PLUGS. OPERATE THE SYSTEM AND NOTE THE AMMETER READ
ING. REPEAT THE PROCEDURE FOR THE RED OR ORANGE WIRE LEADING FROM THE
TOP OF THE CONTROLLER TO THE RIGHT BANK OF THE GLOW PLUGS. OPERATE THE
SYSTEM AND NOTE THE READING.
I
VEHICLE MODEL
NORMAL AMP READINGS
R.V.P
55 MIN
LEFT BANK AMMETER READING

LESS THAN NORMAL
ONE OR MORE GLOW PLUGS ON LEFT

BANK NOT OPERATIVE. CHECK INDIVID
UAL GLOW PLUG LEADS BY CONNECT
ING AMMETER IN SERIES WITH GREEN
WIRE THAT FEEDS GLOW PLUG. OPER
ATE THE SYSTEM AND NOTE THE
READING ON AMMETER. REPEAT PRO
CEDURE FOR EACH GLOW PLUG. EACH
INDIVIDUAL WIRE SHOULD HAVE A
READING OF APPROXIMATELY:
AMMETER READING NORMAL
GLOW PLUG SYSTEM OPERATING NOR

MALLY.
R, V, P = 14 am ps
G VAN = 13 am ps
READINGS NORMAL
RIGHT BANK AMMETER READING

LESS THAN NORMAL
ONE OR MORE GLOW PLUGS ON RIGHT

BANK NOT OPERATIVE. CHECK INDIVID
UAL GLOW PLUG LEADS BY CONNECT
ING AMMETER IN SERIES WITH GREEN
WIRE THAT FEEDS GLOW PLUG. OPER
ATE THE SYSTEM, NOTE THE READING
ON AMMETER. REPEAT PROCEDURE
FOR EACH GLOW PLUG. EACH INDIVID
UAL WIRE SHOULD HAVE A READING
OF APPROXIMATELY:__________________
READINGS LESS THAN NORMAL
ON THOSE CYLINDERS WITH LESS

THAN NORMAL READINGS, CHECK FOR
CONTINUITY THROUGH THE HARNESS
BY DISCONNECTING THE LEAD AND
CONNECTING A 12-VOLT TEST LAMP
FROM THE CONNECTOR TO GROUND.
OPERATE THE GLOW PLUG SYSTEM.
GLOW PLUGS AND HARNESS OK.
| - TEST LAMP LIGHTS
HARNESS OK. REPLACE GLOW PLUG.
TEST LAMP DOES NOT LIGHT

WHEN GLOW PLUGS ARE
OPERATING
REPAIR OR REPLACE HARNESS. RE

TEST GLOW PLUG FOR PROPER OPERA
TION.
IF USING AN IN LINE AMMETER READ BOTH BANKS AT ONCE. DO NOT CUT WIRE.
SNAP-ON METER MT552, VAT-40, OR EQUIVALENT)
F -0 25 1 2
Figure 21Preliminary Diagnosis with an Ammeter
6.2 LITER DIESEL ELECTRICAL SYSTEM DIAGNOSIS

ENGINE DOES NOT START COLD - GLOW PLUGS LAMP MAY OR MAY NOT COME ON.
1. FUEL SYSTEM CHECKED AND IS OK.
2. BATTERY VOLTAGE IS 12.4 VOLTS OR MORE WITH ENGINE CONTROL SWITCH OFF.
3. CRANKING SPEED OK (100 RPM OR MORE).
4. REFER TO ELECTRONIC GLOW PLUG SYSTEM FIGURE FOR WIRING HARNESS TERMINAL IDENTIFICATION.
F-02511
Figure 22Diesel Electrical System Diagnosis

5. Test term inals to ground with a test lamp or the
ohmmeter on a high range. The lamp should be off
or the meter show greater than 1.0 megohm.
6 . Replace the sw itch if it tests open across the
term inals or if either term inal is closed to ground.
7. Disconnect the plug from the switch term inals when
the engine is above 5 2 C (125 F).
8 . Set the ohmmeter on the highest scale or use a
self-powered test lamp.
9. Test across the terminals.
10. Test from each teminal to ground.
11. Switch should be open (test lamp off or high ohm
reading of greater than 1 megohm on the meter).
12. Replace the switch if it is closed.
13. When installing the switch, use a socket wrench.
S w itch to 23 N m (17 ft. lbs.).
GLOW PLUG SYSTEM

If all connections are intact, but the glow plug system
does not operate as stated, do the system diagnosis
shown in figure 21. It provides a fast way to find if the glow
plug system is working properly. Use this procedure
whenever there is doubt about correct system operation.
Then refer to the diagnostic chart in figure 22 to pinpoint
the condition.
GLOW PLUG AFTERSTART

The glow plug controller provides glow plug operation
after starting a cold engine. This after-start operation is
initiated when the engine control switch is returned to
RUN from the START position. W hile loss of this
function may not cause a cold start com plaint, it may
result in excessive white sm oking and/or poor idle quality
after start. To check for proper operation of this circuit
proceed as follows:
1 . With the engine cold 2 7 C (80 F), turn the engine
control switch to the RUN position and let the glow
plugs cycle.
2. After 2 minutes crank the engine for 1 second. (It is
not im portant that the engine starts.) Return the
engine control switch to RUN. Glow plugs should
cycle at least once after cranking.
3. If the plugs do not turn on, disconnect the controller
connector, and c h e c k the c o n n e c to r h arne ss
terminal B with a grounded 12-volt test lamp. The
lamp should be off with the engine control switch in
RUN, and on when the engine is cranked.
4. If the lamp does not operate as just described,
repair a short or open in the engine harness purple
wire.
5. If the lamp works right, but the afterstart glow plug
feature does not, replace the controller.
NOTICE: Do not manually bypass the relay in the

glow plug controller. Do not jum p start with
more than a 12-volt system. The glow plugs
could be damaged.
GLOW PLUG ON-VEHICLE SERVICE

Check the system and its components on the vehicle.
None of the components are serviceable. When install
ing new co m p o n e n ts and m a kin g c o n n e c tio n s , be
sure that connections are tight and torque values are

used. Torque the glow plugs to 17 N m (12 ft. lbs.) when
installed.
CRANKING SYSTEM
DESCRIPTION
CRANKING CIRCUIT
The basic cranking circuit consists of the battery, starter
motor, engine control switch, neutral sensing or neutral
start switch, and related electrical wiring (figure 23).
STARTER MOTOR
Two types of starter motors are used in the vehicles
covered in this manual (figures 24 and 25). Both have the
shift lever m echanism and the solenoid plunger enclosed
in the drive housing to protect them from exposure to dirt,
icing conditions and splash.
In the basic circuit (figure 23), the solenoid w indings are

energized when the switch is closed (in the S ta rt
position). The resulting plunger and shift lever movement
causes the pinion to mesh with the engine flywheel ring
gear and the solenoid main contacts to close, and engine
cranking takes place. When the engine starts, pinion
overrun protects the armature from excessive speed until
the switch is opened, at which time the return spring
causes the pinion to disengage. To prevent excessive
overrun, open the engine control switch (release from the
S tart position) imm ediately when the engine starts.
439
426.
427.
428.
429.
430.
431.
432.
433.
434.
440
442
B u lk h e a d C o n n e c to r
To D is trib u to r BAT T erm inal
BAT.
E n g in e C o n tro l S w itc h
B a tte ry
S ta rte r M o to r
S h ift C o lla r
P in io n C o m p re s s io n S p rin g
C lu tc h
4 3 5 . F ly w h e e l
436.
437.
438.
439.
440.
441.
442.
470.
P in io n
S h ift Lever
P lu n g e r
H o ld In C o il
Pull In C o il
S o le n o id
S o le n o id S w itc h C o n ta c ts
N e u tra l S ta rt S w itc h
F-02510
Figure 23Cranking Circuit
ENGINE ELECTRICAL GD-21

437.
438.
444.
446.
449.
451.
S hift Lever
Plunger
Bearing
Grom met
O verrunning C lutch
Arm ature
1 4*
444
444
449
F-00840
Figure 2410MT Starting Motor
462
S h ift Lever
O verrunning C lu tch
Center Bearing
Center Bearing
R etaining Screw
452. C o n du cto r Banding
437.
449.
450.
451.
457.
458.
459.
460.
461.
Bronze-Graphite B ushing
Grease Reservoir
Sealing G rom m et
Sealing Washers
C adm ium -C opper
C ontact Disc
462. Gasket
458
457
458
452
Figure 2527MT Starting Motor
B-08267
DIAGNOSIS OF CRANKING SYSTEM

NO CRANKING, NO SOUND FROM SOLENOID
TURN HEADLAMPS AND DOME
LAMP ON. TURN KEY TO START.
LAMPS DIM OR GO OUT
CHECK BATTERY STATE-OF-CHARGE

1
GREEN EYE SHOWING
EYE DARK |
jiz ix z z z
CHARGE BATTERY, CHECK FOR
DRAIN, AND CHECK GENERATOR.
CHECK CRANKING VOLTAGE

AT BATTERY POSTS.
9.6 VOLTS OR MORE
LESS THAN 9.6 VOLTS
TEST BATTERY; IF OK,

REPAIR STARTER.
CHECK VOLTAGE FROM ENGINE BLOCK TO BATTERY

NEGATIVE POST, KEY IN START POSITION, VOLTMETER
POSITIVE LEAD ON BLOCK.
0.5 VOLT OR MORE
LESS THAN 0.5 VOLT
CLEAN AND TIGHTEN GROUND CABLE CONNECTION

AND/OR REPLACE CABLE.
CHECK CRANKING VOLTAGE

AT STARTER B TERMINAL.
X
LESS THAN 9.0 VOLTS
9.0 VOLTS OR MORE
CLEAN AND TIGHTEN POSITIVE BATTERY CABLE

TERMINALS AND/OR REPLACE CABLE.
REPAIR STARTER
B-06799
Figure 26Cranking System Diagnosis

Refer to figures 26, 27 and 28 for a diagnosis of the
cranking system. Before removing any unit in the system
for repair, make the following checks.
CRANKING CIRCUIT
BATTERY
D eterm ine the c o n d itio n of the battery. R efer to
Battery earlier in this section for battery diagnosis and
testing.
WIRING
Inspect the circu it w iring for dam age. Inspect all
connections to the starter motor, solenoid, engine control
switch, and battery, including all ground connections.
Clean and tighten all connections as required.
SOLENOID AND CONTROL SWITCHES

C heck all switches to determ ine th eir condition. A
vehicle equipped with an automatic transm ission has a
neutral start switch which allows the vehicle to be started
in Park or Neutral. It is located on the steering column
near the floor. A vehicle with a manual transm ission has a
neutral start switch attached to the clutch.
The P truck with a 7.4L engine has a m agnetic switch in
the cranking circuit (figure 29).
Magnetic Switch Check (Figure 30)

To operate properly, the switch requires at least 11 volts.
Connect a voltmeter across the winding. Close the engine
control switch. If the voltmeter reads less then 11 volts,
locate and repair the problem in the engine control
switch, battery, or wiring. If the voltage reads 11 volts or
above, yet the voltage does not seem to be reaching the
starter, replace the magnetic switch.

SLOW CRANKING, SOLENOID CLICKS OR CHATTERS
STARTER MOTOR NOISE

Refer to the starter noise diagnostic chart. Starter
shims are shown in figure 31 and 32.
the pinion teeth and flywheel teeth are meshed. If

necessary, rotate the flywheel so that a pinion tooth
is directly in the center of two flywheel teeth and on
the centerline of the two gears (figure 34).
6 . Measure the clearance between the top of the
PINION CLEARANCE
1. Remove the lower flywheel housing cover.
2. Inspect the flywheel for signs of unusual wear such
as chipped or m issing gear teeth or the flywheel
being bent. If the flywheel needs replacing, refer to
Engine M echanical earlier in this manual.
3. Start the engine and gently touch the outside
diameter of the rotating flywheel ring gear with chalk
or crayon to show the high point of tooth runout after
the engine is turned off. Turn the engine off and
rotate the flywheel so that the marked teeth are in
the area of the starter pinion gear.
4. Disconnect the negative battery cable to prevent
accidental cranking of the engine.
5. Insert a screwdriver in the small hole in the bottom
of the starter (shown by the arrow in figure 33) and
move the starter pinion and clutch assembly so that
pinion tooth and the bottom of the flywheel tooth

using the width of the wire gage (figure 34). Normal
clearance is 0.5 to 1.5 mm (0.02 to 0.06-inch).
7. If the clearance is less than 0.5 mm (0.02-inch) and
the starter whines after firing, shim the starter away
from the flywheel.
Diesel engine (figure 31):
Add shims as required. Total shim stack must
not exceed 4.0 mm (0.16-inch). If starter shims
are not available, washers made of shim stock
can be used.
Gas engines (figure 32):
Add 1.0 mm (0.04-inch) shims, one at a time, to
both long bolts between starter m ounting pads
and engine until noise problem is corrected.
Do not use more than 2 shims total.
476
475
8 . If the pinion clearance is more than 1.5 mm (0.06
inch) and the starter whines during cranking, shim

the starter towards the flywheel.
Diesel engine (figure 31):
Add a 1.0 mm (0.04-inch) shim between the
starter motor mounting pad and the engine. If
a starter shim is not available, a washer made
of shim stock can be used.
Gas engines (figure 32):
Add 0.38 mm (0.015 inch) shims between the
outboard starter mounting pad and engine
mount until the noise stops. Do not add more
than 4 shims total.
9. When shimming is done, torque the mounting bolts.
Figure 30Magnetic Switch
466.
467.
475.
476.
477.
S h im A = 1.0 m m (0.04-inch)
S h im B = 2 .0 m m (0.08-inch)
Long B o lt
N ut
B o lt
F-02949
Figure 31Shimming Diesel Engine Starter Motors

Tighten
1 . Gas engine starter motor mounting bolts to 38
N-m (28 ft. lbs.) (figure 34).

2. Diesel engine starter motor (figure 31):
Through bolt to 38 N-m (28 ft. lbs.).
Nut to 10 N-m (90 in. lbs.).
Figure 33Meshing Starter and Flywheel Teeth
463
435.
436.
463.
A.
F ly w h e e l
P in io n
S u g g e s te d W ire G age
0.058 m m (0.020-inch) W ire G age
6.355*12.7mm
(1/4"-1/2")
76.2mm
APPROXIMATE
X k~ ( T
463
436
436
B-08268
Figure 34Flywheel to Pinion Clearance
DIAGNOSIS OF STARTER MOTOR NOISE

PROBLEM
POSSIBLE CAUSE
CORRECTION
High-pitched whine
during cranking
(before engine fires)
but engine cranks
and fires normally.
Distance too great between starter pin

ion and flywheel.
Remove shims at the starter mount.

Refer to Starter Motor Noise .
High-pitched whine
after the engine fires
as key is being
released. The engine
cranks and fires
normally. This
complaint is often
diagnosed as starter
hang-in or solenoid
weak .
Distance too small between starter pin

ion and flywheel. Flywheel runout con
tributes to the intermittent nature of the
problem.
Add shims at the starter mount. Refer

to Starter Motor Noise .
A loud whoop after

the engine fires but
while the starter is
still held engaged.
Sounds like a siren if
the engine is revved
while the starter is
engaged.
U sually due to a worn starter motor

clutch.
Remove the starter motor and check

the clutch. Refer to the Light Duty Truck
Unit Repair Manual.
A rumble growl
or (in severe cases) a
knock as the
starter is coasting
down to a stop after
starting the engine.
Usually due to a bent or unbalanced

starter armature.
Remove the starter motor and check

the armature. Refer to the Light Duty
Truck Unit Repair Manual.
CRANKING SYSTEM ON-VEHICLE SERVICE

MAINTENANCE
Keep starter term inals and all other terminals in the
electrical system clean and tight. A loose or corroded
connection or terminal will cause excessive resistance in
the system which will result in hard starting.
At regular intervals, inspect the starting system to
locate and correct potential causes of trouble before the
system performance is affected.
Starting motors do not require lubrication except during
overhaul.
STARTER MOTOR REPLACEMENT
++
1. N egative battery cable.

2. S tarter braces or shie lds if equipped.
3. W ires from the sta rter solenoid.
Raise the vehicle.
4. Two bolts, nuts, washers and shims holding the
starter to the engine.
5. Starter from the engine.
r*+ | Install or Connect
STARTER MOTOR
If the battery, wiring and switches are in satisfactory
condition, and the engine is functioning properly, remove
the motor and refer to the Light Duty Truck Unit Repair
Manual.
Never operate the starter motor more than 30 seconds
at a tim e without pausing to allow it to cool for at least two
minutes. Overheating, caused by excessive cranking, will
damage the motor.
1 . Two bolts, nuts, w asher and shim s th ro ug h the
starter to the engine.
Tighten
Lower the vehicle.
2. Wires to the solenoid terminals.
3. Braces or shields, if equipped.
4. Negative battery terminal.
ENGINE BLOCK HEATERS
6 . B o lt/S c re w
2. O -ring
3. Yoke
4. T erm in al G ro u n d
5. G ro u n d T erm in al
7. S u p p o rt
A. P o s itio n e d
B. In s ta lle d
F-02505
Figure 35 Engine Block Heater
DESCRIPTION
The optional engine block heater is used to preheat
engine coolant for cold weather starting. The unit consists
of a heating coil that fits into the engine block. It has an
attached electrical cord with a plug. If the element fails to
heat the coolant, check the cord and connections before
replacing the element.
ON-VEHICLE SERVICE
REMOVAL
B
1. C oolant, R efer to E N G IN E C O O LIN G (SEC. 6 B).
2. Plug end from the heater.
Loosen the bolt/screw.
3. Heater from the engine block.
INSTALLATION (Figures 35, 36 and 38)
1.
Apply a coating of lubricant to the O-ring and to the

cleaned surface of the plug opening in the block.
2. Install the hairpin end of the heating coil into the
opening and push the support in as far as it will go.
3. Position the block heater as shown for the engine in
figure 38.
Tighten
B olt/screw to 1.8 N m (16 in. lbs.).
4. Route the heater cord so that it does not touch the
engine, hot pipes, manifold, or any moving parts.
Refer to figures 37, 39, 40 and 41.
Coolant. Refer to ENGINE COOLING (SEC. 6 B).
9. H e a te r C ord
Figure 37Heater Cord Wiring,

5.7 L, 7.4 L Engines, P Truck
F-02503
Figure 38Heater Location
A. G-Van
B. RV
F-02502
Figure 39Heater Cord Routing, 4.3L Engine
9.
10.
A.
B.
C.
H e a te r C ord
C ap fo r C ord
5.0L (TBI), 5.7L (TBI) and 7.4L (TBI), RV
5.7L (Carb.), G
5.0L (TBI) and 5.7L (TBI), G
Fz-02950
Figure 40Heater Cord Routing, 5,0L, 5.7L, 7.4L Engines
Figure 41Heater Cord Routing, 6.2L Engine
IGNITION SYSTEM
DESCRIPTION
All ignition systems include a battery, a distributor, an
engine control switch, spark plugs, and the prim ary and
secondary wiring. Information on the battery is located
earlier in this section. Refer to CAB ELECTRICAL (SEC.
8 A) for information on the engine control switch.
158
There are two different igintion systems used on these

vehicles. If the vehicle has a carbureted engine, spark is
controlled by the module inside the distributor with an
integral coil. If the vehicle engine is equipped with throttle
body injection (TBI), the ignition system includes a knock
sensor, an electronic spark control module, a computer
(ECM), and a distributor with a separate coil.
DISTRIBUTOR
The distributor with an integral coil combines all ingition
components in one unit (figures 42 and 43). The coii is in
the cap and connects through a resistance brush to the
rotor. On a d istribu to r w ith a separate coil the coil
connects to the rotor through a high tension wire (figure
44).
The d is trib u to r has an inte rn a l m agnetic pick-up
assembly which contains a permanent magnet, a pole
piece with internal teeth and a pick-up coil. When the
teeth of the tim er core, rotating inside the pole piece, line
up with the teeth of the pole piece, an induced voltage in
the pick-up coil signals the electronic module to trigger
the coil primary circuit. The prim ary current decreases
and a high voltage of up to 35,000 volts is induced in the
ignition coil secondary winding. This voltage is directed
through the rotor and secondary leads to fire the spark
plugs. The capacitor in the distributor is for radio noise
suppression.
The magnetic pick-up assembly is mounted over the
main bearing on the distributor housing. On carbureted
engines without computers, the assembly is made to
rotate by the vacuum control unit, thus providing vacuum
a dva nce . T he d is trib u to r sh a ft is m ounted on the
camshaft at the rear of the engine, and rotates at one-half
the rpm of the engine. The force of rotation moves the
advance w eights against the springs, and provides
cetrifugal advance to the tim er core.
ENGINES WITH TBI

On e ng in es w ith TBI, spark tim in g changes are
determined electronically by the ECM (computer), which
m onitors info rm a tio n from va riou s eng in e sensors,
com putes the desired spark tim ing, and signals the
distributor.
The distributor does not contain centrifugal weights,
springs, or a vacuum advance unit.
Each TBI equipped engine also has a knock sensor
mounted in the engine block and connected by a blue
wire to a spark control module (called a half-function
box ) (figure 45). In response to engine knock, a signal is
sent from the sensor to the module and then to the ECM,
152. B a tte ry T erm in al

(C o n n e c te d to Ig n itio n S w tic h )
153. V a cuu m U n it
156. Tach T erm in al
158. G ro u n d T erm inal
B-09832
Figure 42Distributor with Integral Coil

which computes how much to retard spark tim ing to
reduce knock. A retard command is then sent to the
distributor.
Information on TBI and the computer controlled ignition
system, system com ponents and th eir locations, and
diagnostic charts are located in the Light Duty Truck Fuel
IGNITION TIMING
Timing specifications for each engine are listed on the
V ehicle E m issions C ontrol Inform ation label on the
radiator support. Always follow Vehicle Emissions Control
Inform ation label procedures when adjusting tim ing.
When using a tim ing light, connect an adapter between
the number 1 spark plug and the num ber 1 spark plug
wire, or use an inductive type pick-up. Do not pierce the
plug lead. Once the insulation of the spark plug cable has
been broken, voltage will jum p to the nearest ground, and
the spark plug will not fire properly.
153.
154.
159.
160.
V a cuu m U n it
C o n n e c to r
C over
C o il
151.
152.
155.
157.
158.
161. Cap
162. R o to r
163. G ear
B-09833
Figure 43Distributor Components
Ig n itio n C o il C o n n e c to r T e rm in a ls
B a tte ry T erm inal
Tach and C o il T erm in al
C o il Lead
F o u r T erm inal C o n n e c to r
F-02498
Figure 44Distributor with Sealed Module
Connectors and Separate Coil
R e s is to r
14 m m Thread
H eat Range
Taper Seat
E x te n d e d T ip
El-09847
Figure 46Spark Plug Coding
F-02497
Figure 45Knock Sensor and Spark Control

Module on P Truck
Some engines incorporate a magnetic tim ing probe
hole for use with special electronic tim ing equipment.
C o n su lt m a n u fa ctu re rs in s tru c tio n s fo r use of th is
equipm ent.
Normal or average service is assumed to be a m ixture

of idling, slow speed, and high speed operation with some
of each making up the daily total driving. Occasional or
intermittent high-speed driving is essential to good spark
plug performance as it provides increased and sustained
combustion heat that burns away any excess deposits of
carbon or oxide that may have accumulated from frequent
idling or continual stop-and-go or slow-speed driving.
Spark plugs are protected by an insulating nipple made of
special heat-resistant material which covers the spark
plug terminal and extends downward over a portion of the
plug insulator. These nipples prevent flash-over with
resultant missing of engine, even though a film is allowed
to accumulate on exposed portion of plug porcelains.
Do not mistake corona discharge for flash-over or a
shorted insulator. Corona is a steady blue light appearing
SPARK PLUG WIRES

The spark plug wiring is a carbon impregnated cord
conductor encased in an 8 mm diameter rubber jacket.
The silicone spark plug boots form a tight seal on the
plugs. Refer to Spark Plug W ires later in this section for
service precautions.
Numbers relate to thread size as follows:

1st number denotes THREAD SIZE
4
10
12
SPARK PLUGS
Resistor type, tapered seat spark plugs are used on all
engines. No gasket is used on these tapered seat plugs.
Refer to figures 46 and 47 for an explanation of letter
coding on spark plugs. Refer to the Vehicle Emissions
C ontrol Inform ation label on the radiator support for
correct gap information.
14 m m
18 m m
10 m m
12 m m
1/2 -in ch ta p e r
1/2-inch
3/4-inch
7/s-inch
2nd number denotes HEAT RANGE

0-1-2-3-4-5-6-7-8-9
C O L D -------------HOT
F-02496
Figure 47Spark Plug Coding Chart

around the insulator, just above the shell crimp. It is the
visible evidence of a high-tension field, and has no effect
on ignition performance. Usually it can be detected only in
darkness. This discharge may repel dust particles, leaving
a clear ring on the insulator just above the shell. This ring
is som etim es m istakenly regarded as evidence that
combustion gases have blown out between shell and
insulator.
TEST FOR SEPARATELY MOUNTED COIL

1. Disconnect the distributor lead and wiring from the
coil.
2. Connect an ohm meter as shown in figure 48, step 1.
Use the high scale. The reading should be infinite. If
not, replace the coil.
3. Connect the ohm meter as shown in step 2. Use the
low scale. The reading should be very low or zero. If
not, replace the coil.
4. Connect the ohm meter as shown in step 3. Use the
high scale. The meter should not read infinite. If it
does, replace the coil.
5. Reconnect the distributor lead and wiring to the coil.
A. S crape clea n m eta l g ro u n d .

F-02117
Figure 48Testing the Ignition Coil
DIAGNOSIS OF THE IGNITION SYSTEM

DISTRIBUTOR/TIMING SYSTEM
FOR TBI-EQUIPPED VEHICLES
IGNITION SYSTEM FOR

CARBURETED ENGINE

1 . Engage the parking brake and block the
wheels.
2. Place the automatic transmission in park or
the manual transmission in neutral.

1. Engage the parking brake and block the
wheels.
2. Place the automatic transmission in park or
the manual transmission in neutral.
1. Refer to the Fuel and Emissions Service Manual for

information on the computerized ignition system,
including the diagnostic use of the Check Engine
or Service Engine Soon lamp.
2. Refer to the Light Duty Truck Unit Repair Manual for
distributor com ponent checks.
1. Refer to figure 49, 50 and 51 for system diagnosis.

2. Refer to the Light Duty Truck Unit Repair Manual for
distributor component checks.
ENGINE CRANKS, BUT WILL NOT START

(DISTRIBUTOR WITH INTEGRAL COIL)
IF A TACHOMETER IS CONNECTED TO THE TACHOMETER TERMINAL, DISCONNECT IT BEFORE PROCEEDING WITH THE TEST.
2. CHECK VOLTAGE AT DISTRIBUTOR BAT TERMINAL WHILE CRANKING.
7 VOLTS OR MORE
UNDER 7 VOLTS
1 "
3. WITH ENGINE CONTROL SWITCH ON ,
CHECK TACH" TERMINAL VOLTAGE.
REPAIR PRIMARY CIRCUIT TO ENGINE CONTROL SWITCH.
I
UNDER 1 VOLT
1 TO 10 VOLTS
10 VOLTS OR MORE
REPLACE MODULE AND CHECK FOR

SPARK FROM COIL AS IN STEP 6.
REPLACE IGNITION COIL
SPARK
INSPECT CAP FOR
WATER, CRACKS,
ETC. IF OK, RE
PLACE ROTOR.
MH
QPADk'
NU orH
n fV
SPARK
REMOVE PICKUP COIL LEADS FROM MODULE. CHECK TACH.

TERMINAL VOLTAGE W/ENGINE CONTROL SWITCH "O N .
WATCH VOLTMETER AS TEST LIGHT IS MOMENTARILY CON
NECTED FROM BATTERY TO MODULE P " (VIEW D, FIGURE 44)
NOT MORE THAN 5 SECONDS.
NO DROP IN VOLTAGE
-------
I
CHECK MODULE GROUND AND FOR OPEN IN WIRES FROM
CAP TO DISTRIBUTOR. IF OK, REPLACE MODULE.
NO SPARK
SYSTEM
OK
VOLTAGE DROPS
6. CHECK FOR SPARK FROM COIL WITH ST-125 AS TEST
LIGHT IS REMOVED FROM MODULE TERMINAL.
F-02494
Figure 49Ignition System Diagnosis
-------188
CUT BOOT HERE
11 mm (7/ie IN.)
FROM TIP OF
SPARK PLUG
VIEW A
192
VIEW B
194
VIEW C
VIEW D
168. S park P lug B o o t
189. D iscard
191. In se rt B o o t O ver P o rcelain End O f ST-125
192.
193.
194.
195.
196.
197.
C o n n e c t To G ro u n d
Leave H a rn e ss C o n n e c te d
R em ove Leads To M o d u le
To BAT +
Test L ig h t
C o n n e c t V o ltm e te r A n d Tach T erm inal To G ro u n d
F-00251

INTERMITTENT OPERATION OR MISS
F-02495
DIAGNOSIS OF SPARK PLUGS

PROBLEM
Brown to grayish-tan
deposits and slight
electrode wear.
Dry, fluffy black
carbon deposits.
POSSIBLE CAUSE
Normal wear.
1. Carburation is too rich.

2. S ticking EFE valve or m anifold heat
valve.
3. Sticking automatic choke.
4. Poor ignition output.
Wet, oily deposits

with very little
electrode wear.
Red, brown, yellow

and white colored
coatings on insulator.
Engine misses
intermittently under
severe operating
conditions.
1. Break-in of new or recently overhauled

engine.
2. Excessive valve stem guide clearances.
3. Worn intake valve seals.
By-products of combustion.
CORRECTION
Clean, regap, reinstall.
1. Check the fuel mixture. Replace the air

cleaner if clogged.
2. Replace if necessary.
3. Refer to CARUBRETORS (SEC. 6C1).
4. Check the distributor coil connections
and cables (discussed in this section).
Refer to the Fuel and Emission Service
Manual.
1. Degrease, clean and reinstall the plugs.
2. Refer to ENGINE (SEC. 6 A).
3. Replace the seals.
Clean, regap, and reinstall. If heavily
coated, replace.
DIAGNOSIS OF SPARK PLUGS (CONT.)

PROBLEM
POSSIBLE CAUSE
CORRECTION
Colored coatings
heavily deposited on
portion of the plug
projecting into the
chamber and on the
side facing the intake
valve.
Leaking seals if the condition is found in

only one or two cylinders.
Check the seals. Replace if necessary.

Clean, regap, and reinstall the plugs.
Shiny yellow glaze

coating on the
insulator.
Melted by-products of combustion.
Avoid sudden acceleration with wideopen throttle after long periods of low
speed driving. Replace the plugs.
Burned or blistered
insulator tips and
badly eroded
electrodes.
Overheating.
Broken or cracked
insulator tips.
Heat shock from sudden rise in the tip

temperature under severe operating conditons. Improper gapping of the plugs.
1 . Check the cooling system.

2. Check for sticking heat riser valves. Re
fer to ENGINE (SEC. 6 A).
3. Check the air-fuel mixture. May be too
lean. Refer to the Fuel and Emissions
Service M anual for TBI engines or
C ARBURETORS (SEC. 6C1) in this
manual for carbureted engines.
4. Check the heat range of the plugs. May
be too hot.
5. Check the ignition tim ing. May be over
advanced.
6 . Check the torque value of the plugs to
ensure good plug-engine seat contact.
Replace the plugs. Gap correctly.
IGNITION SYSTEM ON-VEHICLE SERVICE

SERVICE PRECAUTIONS
Some service tachometers and electronic diagnostic
equipment may NOT be compatible with these ignition
systems. Consult your representative of such equipment
to update your equipm ent for com patibility with these
systems.
1. When making compression checks, disconnect the
engine control switch feed wire at the distributor.
When disconnecting this connector release the
locking tab while pulling downward on the connector
body; do not use a screwdriver or tool to release the
locking tab as it may break the tab.
2 . No p eriodic lub rica tion is required. Engine oil
lu b rica te s the low er bush in g and an o il-fille d
reservoir provides lubrication for the upper bushing.
NOTICE: the tachom eter terminal must NEVER
be allowed to touch ground, as damage to the
module and/or ignition coil can result.
3. On integral coil distributors, the tachometer (TACH)

terminal is next to the engine control switch (BAT)
connector on the distributor cap. On distributors
with separate coils, the TACH terminal is at the coil
(figure 44).
4. There is no dwell adjustment since this is controlled
by the module.
5. The material used to construct the spark plug wires
is very pliable and soft. This wire will withstand more
heat and carry a higher voltage. Due to the more
pliable wire, scuffing and cutting become easier.
Route the spark plug wires correctly to prevent
chaffing or cutting. When removing a spark plug
wire from a spark plug, twist the boot on the spark
plug and pull on the boot to remove the wire.

DISTRIBUTOR REPLACEMENT
Some components, such as the engine cover or air
cleaner, may need to be removed to reach the distributor.
DISTRIBUTOR WITH INTEGRAL COIL
++
1. Engine control sw itch battery feed w ire from the

d istribu to r cap.
2. Tachom eter lead (if equ ip pe d ) from the cap.
3. Ignition coil co nn ecto r from the cap.
Do not use a screwdriver or tool to release the
locking tabs.
4. D istrib u to r cap by pre ssin g down on the four
spring-loaded screws and turning the latches to the
left.
5. Vacuum hose from the vacuum advance unit (if
equipped).
6 . Distributor clamp bolt and hold-down clamp from
the engine.
Note the position of the rotor, then pull the
distributor up until the rotor just stops turning
to the left and again note the position of the
rotor.
7. Distributor.
To ensure correct tim ing of the distributor it must be
installed with the rotor correctly positioned as noted in
Step 7 of the removal procedure.
If the engine was a c c id e n ta lly cranked a fte r the
distributor was removed, the following procedure can be
used for installation:
Remove the num ber 1 spark plug.
Place finger over the number 1 spark plug
hole and c ra n k th e e n g in e s lo w ly u n til
compression is felt.
Align the tim ing mark on the pulley to 0 on
the engine tim ing indicator.
Turn the rotor to point between number 1 and
number 8 spark plug towers on the distributor
cap on V 8 engines and between number 1 and
number 6 on 6 cylinder engines.
1. Distributor.
If the distributor shaft w ont drop into the
engine, first insert a screwdriver into the hole
for the distributor and turn the oil pump drive
shaft.
2. Distributor hold-down clam p and clamp bolt.
3. Vacuum hose to the vacuum unit (if equipped).
DISTRIBUTOR WITH SEPARATE COIL

2. W iring harness connectors at the side of the
d istribu to r cap.
3. D istrib uto r cap and move it out of the way.
Scribe a mark on the engine in line with the
rotor.
Note the position of the distributor housing in
relation to the engine.
4. Distributor hold-down nut and clamp.
5. Distributor.
Install or Connect
To ensure correct tim in g of the d is trib u to r it m ust
be installed w ith the rotor correctly p ositioned as
noted in step 3 of the rem oval procedure.
If the d is trib u to r sh aft w on t drop into the engine,
in s e rt a s c r e w d r iv e r in to th e h o le fo r th e
d istrib u to r and tu rn the oil pum p driveshaft.
1. Distributor.
2. H old-dow n nut and clam p.
3. D istrib uto r cap.
4. W iring harness co nn ecto r at the side of the cap.
5. Engine cover and console.
6 . N egative battery cable.
COIL REPLACEMENT
++

2. Engine control sw itch and ta cho m e te r te rm in a ls
at the coil.
3. Coil to d is trib u to r lead at the coil.
4. Nuts holding the coil bracket and coil to the
e ngine bracket.
5. Coil bracket and coil.
Drill and punch out the two rivets holding the
coil to the bracket.
6 . Coil from bracket.
Install or Connect
Coil to the bracket w ith two screws.
Coil bracket to the engine bracket w ith stu ds and
nuts.
Coil to the d is trib u to r lead at the coil.
Engine control sw itch and ta cho m e te r connectors
to the coil.
N egative battery cable.
IGNITION TIMING
4. Cap on the distributor.

The aligning tab on the cap should engage
with the notch in the housing.
5. Four hold-down spring latches.
6 . Ignition coil connector to the cap.
7. Engine control switch battery feed wire.

8 . Tachometer lead (if equipped).
Set ignition tim ing as described later in this

section.
1. Refer to the Vehicle Emissions Control Information

label located on the radiator support. Follow all
instructions on the label.
2. Refer to the Fuel and Emissions Service Manual for
tim ing information for engines equipped with TBI.
3. With the engine control switch off, connect the
pick-up lead of a tim ing light to the num ber 1 spark
plug. Use a jum per lead between the wire and plug
or an inductive type pick-up. DO NOT pierce the wire

SPARK PLUG WIRE
REPLACEMENT
4.
5.
6.
7.
or attempt to insert a wire between the boot and the

w ire . C o n n e c t th e tim in g lig h t p o w e r le a d s
according to the m anufacturers instructions.
Disconnect the vacuum hose from the distributor if
so equipped.
Start the engine and aim the tim ing light at the
tim ing mark (figure 52). The line on the balancer or
pulley will line up at the tim ing mark. If a change is
necessary, loosen the distributor hold-down clamp
bolt at the base of the distributor. W hile observing
the mark with the tim ing light, slowly rotate the
distributor until the line indicates the correct timing.
Tighten the hold-down bolt, and re-check the timing.
Turn off the engine and remove the tim ing light.
R e co n n e ct the n u m b e r 1 sp ark plu g w ire, if
removed.
Connect the vacuum hose to the distributor if so
equipped.
SPARK PLUG WIRES

PRECAUTIONS
1. Twist boots 1/2 turn before removing.
2. When removing the boot, do not use pliers or other
tools that could tear the boot.
3. Do not force anything between the wire and the
boot, or through the silicone jacket of the wire.
4. Do not pull on the wires to remove the boot. Pull on
the boot, or use a tool designed for this purpose.
5. Special care should be exercised when installing
spark plug boots to assure that the metal terminal
within the boot is fully seated on the spark plug
terminal and that the boot has not moved on the
wire. If boot to wire movement has occurred, the
boot will give a false visual impression of being fully
seated. A good check to assure that boots have
been properly assembled is to push sideways on the
installed boots. If they have been correctly installed,
a stiff boot with only slight looseness will be noted. If
the terminal has not been properly seated on the
spark plug, only the resistance of the rubber boot
will be felt when pushing sideways.
Wire routings must be kept intact during service, and

followed exactly when wires have been disconnected, or
when replacement of the wires is necessary. Failure to
route the wires properly can lead to radio ignition noise
and crossfiring of the plugs, or shorting of the leads to
ground. For the correct wiring routing for each engine,
refer to figures 53 through 61.
Some d is trib u to rs have s p a rk plug w ire retainer
harness assemblies with the engine firing order marked
on them. If the firing order is not indicated, install the plug
wires according to the firing order as shown in figures 62,
63 and 64. When the wiring is completed, the plug wire
from cylinder number 1 should lead to the distributor
tower at the front and on the same side of the engine as
cylinder num ber 1 . The plug wire from cylinder number 6
(in 6 cylinder engines) or from cylinder num ber 8 (in V 8
engines) should lead to the distributor tower at the front of
the engine next to the number 1 tower.
Be sure to position all plug boots perpendicular to the
centerline of the engine.
On the LE 8 (7.4 L V 8 ) engine, the spark plug harness
assembly and a dielectric paper insulator are fitted to a
shield which is installed over the spark plug (figure 65).
The insulator grounds the shield to the engine block. If
the assembly is removed from the shield, make sure that
th e in s u la to r is p re s e n t and u n d a m a g e d b e fo re
reinstallation.
Figure 53Spark Plug Wire Routing for the 7.4L (Carb.) Engine - P Truck (Federal)
Figure 54Spark Plug Wire Routing for the 7.4L (Carb.) Engine - P Truck (California)
Figure 55Spark Plug Wire Routing for the 7.4L (TBI) Engine
Figure 56Spark Plug Wire Routing for the 5.7L (Carb.) Engine - P Truck (California)
Figure 57Spark Plug Wire Routing for the 5.7L (Carb.) Engine - G Van, P Truck (Federal)
#5
#7
175. C oil W ire

F-02488
Figure 58Spark Plug Wire Routing for the 5.7L (TBI) Engine - P Truck
Figure 59Spark Plug Wire Routing for the 5.0L (TBI) and 5.7L (TBI) Engine - RV,G
Figure 60Spark Plug Wire Routing for the 4.3L (TBI) Engine - G Van
Figure 61Spark Plug Wire Routing for the 4.3L (TBI) Engine - RV
(a
<?> j1
FIRING
ORDER
1-6-5-4-3-2
\J
I i) ( ) d> Jr
3
F-00262
Figure 63Spark Plug Wire Schematic (V6 Engines)
Figure 64Spark Plug Wire Schematic (V8 Engines)
ENGINE WIRE HARNESS

When it necessary to move any of the wiring, whether
to lift wires away from their harnesses or move harnesses
to reach some component, take care that all wiring is re
placed in its original position and all harnesses routed
correctly. If clips or retainers break, replace them. Electri
cal problems can result from wiring or harnesses becom
ing loose and moving from their original positions or from
being rerouted. Refer to figures 66 through 94 for the cor
rect routing of engine wiring.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
W in d s h ie ld W ip e r M o to r
H y d ra u lic C lu tc h R e se rvo ir H ose
B u lkh e a d C o n n e c to r
H eat S h ie ld
K n o ck S e n so r
W a te r Temp. S w itc h /S e n s o r
D is trib u to r
G rou nd
O il P ressure S e n s o r
O il P ressure S w itc h /S e n s o r
0 2 Sensor
VIEW A
F-02484
Figure 66Engine Wiring for the 4.3L (TBI) - RV - Left Side
1.
2.
3.
4.
8.
9.
10.
11.
12.
24.
28.
B u lkh e a d C o n n e c to r
D is trib u to r
G ro u n d
O il P ressure S w itc h
0 2 Sensor
C o il
E n g in e Temp. S w itc h
B-07749
Figure 67Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - RV - Left Side
VIEW A
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
ECM M o d u le
F uel P um p R elay
S ta rte r
M 40 D o w n s h ift Relay
A.I.R. S w itc h Valve
G e n e ra to r
C o o la n t Temp. S e n s o r
ESC H a lf F u n c tio n Box
T h ro ttle P o s itio n S e n s o r
I.A.C. A c tiv a to r
M AP S e n s o r
C oil
EGR S o le n o id
G ro u n d W ire
G e n e ra to r M o u n tin g B racket
B-07751
Figure 68Engine Wiring for the 4.3L (TBI) - RV - Right Side
6.
13.
14.
16.
17.
18.
19.
20.
21.
22.
23.
25.
K nock S ensor
ECM M o d u le
Fuel P u m p R elay
M 40 D o w n s h ift R elay
A.I.R. Valve
G e n e ra to r
M AP S ensor
EGR S o le n o id
B-07750
Figure 69Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - RV - Right Side
1.
2.
4.
7.
9.
11.
9.
9.
0.
J u n c tio n B ox
W a te r Temp. S e n so r
G ro u n d
O il P re ssure S w itc h
E n g in e E x h a u s t S e n d e r
O il P re ssure S e nd e r
B-07691
Figure 70Engine Wiring for the 7.4L (TBI) - RV - Left Side
13.
14.
16.
18.
21.
23.
24.
31.
32.
33.
34.
ECM M o d u le
F uel P u m p Relay
G e n e ra to r
M A P S e n so r
C o il
B a tte ry C able
A u x ilia ry C o o lin g Fan
A.I.R. D ive rte r Valve
In je c to r
B-07692
Figure 71Engine Wiring for the 7.4L (TBI) - RV - Right Side
VIEW A
VIEW B
9.
15.
18.
28.
31.
35.
36.
37.
38.
39.
40.
G ro u n d
S ta rte r
G e n e ra to r
E n g in e Temp. S e n s o r
B a tte ry C able
S peed S e n s o r
F uel F ilte r
G lo w P lug In h ib it S w itc h
F ast Id le S o le n o id
G lo w P lug
C o ld and F ast Id le S w itc h
VIEW C
B-07693
Figure 72Engine Wiring for the 6.2L Diesel - RV - Right Side
VIEW
1.
2.
3.
7.
10.
11.
39.
41.
42.
W a te r Temp. S w itc h /S e n s o r
G lo w P lug
EGR/EPR S o le n o id
G lo w P lug C o n tro lle r C o n n e c to r
B-07694
Figure 73Engine Wiring for the 6.2L Diesel - RV - Left Side
4.
14.
15.
16.
17.
18.
21.
23.
24.
Fuel P um p Relay
S ta rte r
A.I.R. Valve S w itc h
G e n e ra to r
MAP Sensor
C o il
25.
31.
34.
47.
48.
49.
50.
51.
EGR S o le n o id
B a tte ry C able
In je c to r
W ip e r Pum p
Fuel P um p P rim e r C o n n e c to r
C o o la n t Temp. S w itc h
Tach C o n n e c to r
Id le A ir S w itc h
B-07696
Figure 74Engine Wiring for the 4.3L (TBI) - G Van - Left Side
6 . K n o c k S e n so r
8.
12.
30.
43.
44.
45.
46.
D is trib u to r
0 2 S e n so r
O il P ressure S e n d e r
O il P re ssu re /F u e l P u m p S w itc h
Temp. S e n s o r
Fuel P um p W irin g H a rn e ss
G rou nd S tra p T erm in al
B-07695
Figure 75Engine Wiring for the 4.3L (TBI) - G Van - Left Side
8.
12.
24.
30.
43.
44.
46.
50.
52.
53.
D is trib u to r
0 2 Sensor
C o il
O il P re ssu re /F u e l P um p S w itc h
Temp. S e n s o r
G ro u n d S tra p Term inal
Tach C o n n e c to r
F uel L in e s
Fuel P um p W irin g H a rn e ss
B-07697
Figure 76Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - G Van - Left Side

34
16
4.
6.
14.
15.
16.
22.
23.
34.
48.
54.
Knock S ensor
F uel P u m p R elay
S ta rte r
M 40 D o w n s h ift R elay
G e n e ra to r
M AP S e n s o r
EGR S o le n o id
B a tte ry C able
A.I.R. D iv e rte r Valve
In je c to r
Fuel P um p P rim e r C o n n e c to r
A/C C o n n e c to r
B-07698
Figure 77Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - G Van - Right Side
7. W a te r Temp. S w itc h
8. D is trib u to r
10. O il P ressure S e n so r
11. O il P ressure S w itc h
26.
45.
58.
72.
73.
74.
75.
78.
79.
80.
G ro u n d W ire
F uel P um p W irin g H a rn e ss
E n g in e H a rn e ss
G ro u n d S trap
T ra n s m is s io n S w itc h
V acuum Pipe
H ig h F lo w A ir Valve
T h ro ttle Valve (W ith o u t A/C)
T h ro ttle Valve (A/C)
S peed S w itc h R elay
CALIFORNIA
B-07699
Figure 78Engine Wiring for the 5.7L (Carb.) - G Van - Left Side
VIEW A
FEDERAL
15.
18.
25.
31.
58.
75.
76.
77.
81.
S ta rte r
G e n e ra to r
EGR S o le n o id
B a tte ry C able
H ig h F lo w A ir Valve
E le c tric C h o ke
A.I.R. P um p
C ho ke
77
CALIFORNIA
B-07700
Figure 79Engine Wiring for the 5.7L (Carb.) - G Van - Right Side
36
7.
30.
31.
36.
39.
42.
53.
55.
59.
60.
61.
62.
63.
64.
65.
W a te r Tem p S w itc h
B a tte ry C able
F uel F ilte r
G lo w Plug
G lo w Plug C o n tro lle r C o n n e c to r
F ue l P um p W irin g H a rn e ss
EPR V a cuu m Pipe
W a te r S e n s o r C o n n e c to r
Temp. S w itc h
F uel P ressure C o n n e c to r
F uel H e a te r C o n n e c to r
G lo w P lug C o n tro lle r
EPR S o le n o id
H y d ro -B o o s te r B ra cket
VIEW B
B-07701
Figure 80Engine Wiring for the 6.2L Diesel - G Van - Left Side
66
31
FtfT #
15.
18.
31.
39.
66.
67.
68.
69.
S ta rte r
G e n e ra to r
B a tte ry C able
G lo w P lug
W in d s h ie ld W a sh e r Pum p
C o ld A d van ce
C o ld A d va n ce and Fast Idle
F uel S h u to ff
VIEW A
70. C o o la n t Probe
71. F ast Id le S o le n o id C o n n e c to r
B-07702
Figure 81Engine Wiring for the 6.2L Diesel - G Van - Right Side
CALIFORNIA
8.
80.
82.
83.
84.
D is trib u to r
Speed S w itc h Relay
A n ti-D ie s e l S o le n o id
M o d u la to r Pipe
T h ro ttle R eturn Valve
B-07647
Figure 82Engine Wiring for the 5.7L (Carb.) - P Truck - Left Side
31
58
VIEWC
FEDERAL
CALIFORNIA
15.
18.
31.
58.
81.
85.
VIEW A
S ta rte r
G e n e ra to r
B a tte ry C able
C ho ke
N e g a tive B a tte ry C able
B-07648
Figure 83Engine Wiring for the 5.7L (Carb.) - P Truck - Right Side
D is trib u to r
0 2 S ensor
G e n e ra to r
C o il
G ro u n d W ire
O il P ressure S e nd e r
B-07649
Figure 84Engine Wiring for the 5.7L (TBI) - P Truck - Left Side
Knock S ensor
MAP S ensor
EGR S o le n o id
B a tte ry C ab le
In je c to r
E n g in e H a rn e s s
Id le and A ir C o n tro l A c tiv a to r
B-07650
Figure 85Engine Wiring for the 5.7L (TBI) - P Truck - Right Side
CALIFORNIA
8.
11.
30.
60.
80.
87.
88.
89.
D is trib u to r
O il P re ssure S e nd e r
Tem p S w itc h
Speed S w itc h Relay
T ra n s m is s io n S o le n o id
E n g in e S peed S w itc h S o le n o id
A ir C le a n e r S e n so r
B-07652
Figure 86Engine Wiring for the 7.4L (Carb.) - P32 Truck - Left Side
VIEW C
CALIFORNIA
VIEW B
15.
18.
31.
33.
58.
S ta rte r
G e n e ra to r
B a tte ry C able
A.I.R. D ive rte r Valve
E n g in e H arne ss
81. C ho ke
90. S ta rte r M o to r M a g n e tic S w itc h
91. Fuel Pipe
B-07651
Figure 87Engine Wiring for the 7.4L (Carb.) - P32 Truck - Right Side
\
8.
11.
24.
30.
60.
89.
92.
D is trib u to r
C o il
O il P re ssure S e n d e r
Temp. S w itc h
A ir C le a n e r S e n s o r
P ow er S te e rin g P um p
B-07567
Figure 88Engine Wiring for the 7.4L (Carb.) - P42 Truck - Left Side
15.
18.
31.
33.
58.
81.
S ta rte r
G e n e ra to r
B a tte ry C able
C ho ke
B-07653
Figure 90Engine Wiring for the 7.4L (Carb.) - P42 Truck - Right Side
15.
18.
31.
39.
58.
71.
93.
94.
95.
S ta rte r
G e n e ra to r
B a tte ry C able
G lo w P lug
F ast Id le S o le n o id C o n n e c to r
H e a te r C o n n e c to r
C o ld A d va n ce C o n n e c to r
F ue l S h u to ff Valve C o n n e c to r
B-07703
Figure 91Engine Wiring for the 6.2L Diesel - P Truck - Right Side
28.
30.
58.
61.
63.
87.
96.
97.
Temp. S w itc h
E n g in e H arne ss
F ue l P ressure C o n n e c to r
T ra n s m is s io n S o le n o id
F uel H e a te r C o n n e c to r
B-07704
Figure 92Engine Wiring for the 6.2L Diesel - P32 Truck - Back of Engine
O il P re ssure S e n d e r
F uel P re ssure C o n n e c to r
B-07705
Figure 93Engine Wiring for the 6.2L Diesel - P42 Truck - Back of Engine
P (32)
15.
31.
58.
93.
S ta rte r
B a tte ry C a b le
H e a te r C o n n e c to r
B-07706
Figure 94Engine Wiring Starter Motor for the 6.2L Diesel - P32 and P42 Truck
SPECIFICATIONS
BATTERY SPECIFICATIONS
Volts
Cold Cranking
Amperes Rating
@ -18 C (0 F)
Reserve
Capacity
(Minutes at
25 Amps)
Part No.
Application
Catalogue
Replacement
Number
1980337
1200
12
550
130
270
1980474
1110
12
625
160
310*
1981729
RV, G
729
12
430
90
210
1981730
RV,G,P
730
12
525
40
260
1981733
RV, G, P
733
12
540
115
270
1981734
RV, G, P
734
12
630
115
310
Load Test
(Amperes)
* Battery tester cable clamps should be between term inal nuts and lead pads of term inals. If not possible, load value should be 275
amperes.
GENERATOR SPECIFICATIONS
Part No.
Series
(Type 100)
Rotation
Viewing
Dr. End
Field Current
@ 12 Volts
27C (80F)
AMPS
AMPS
RPM
AMPS
RPM
AMPS
1100207
12 SI
CW
4 .5 -5 .0
23
1600
70
6500
66
1101205
17-SI
cw
1.7-2.1
50
1600
120
6500
120
1101240
12 SI
CW
4 .2 -5 .0
30
1600
94
6500
94
1101241
12 SI
CW
4 .2 -5 .0
30
1600
94
6500
94
1101242
12 SI
CW
4 .5 -5 .0
23
1600
66
6500
66
1101243
12 SI
CW
4 .2 -5 .0
23
1600
66
6500
66
1101244
12 SI
CW
4 .0 -5 .0
23
1600
66
6500
66
1101245
12 SI
CW
4 .2 -5 .0
30
1600
94
6500
94
1105628
12 SI
CW
4 .5 -5 .0
30
1600
81
6500
78
1105632
12 SI
CW
4 .5 -5 .0
23
1600
70
6500
66
1105661
CS 130
CW
6 .0 -7 .5
42
1600
105
6500
105
1105688
CS 130
CW
6 .0 -7 .5
36
1600
100
6500
100
1105710
CS 130
CW
4 .8 -5 .7
30
1600
85
6500
85
1105711
CS 130
CW
6 .0 -7 .5
36
1600
100
6500
100
1105712
CS 130
CW
4 .8 -5 .7
30
1600
85
6500
85
1105718
CS 130
CW
6 .0 -7 .5
42
1600
105
6500
85
1105720
CS 130
CW
6 .0 -7 .5
42
1600
105
6500
105
Cold (lutput
Hot Output
SPECIFICATIO NS (CONT.)
GENERATOR APPLICATIONS
Generator
Part Number
K22
1101241
25
18
47
35
K81
1101242
25
18
47
35
K22
1101240
25
18
47
35
K68
1105720
25
18
47
35
K81
1101243
25
18
47
35
K22
1101240
25
18
47
35
K68
1105720
25
18
47
35
K81
1101243
25
18
47
35
K64
1105628
27
20
43
32
K81
1105632
27
20
43
32
K68
1105661
25
18
50
37
K81
1101244
25
18
50
37
K22
1101245
25
18
50
37
K60
1105711
25
18
50
37
K99
1105710
25
18
50
37
K60
1105711
25
18
50
37
K99
1105710
25
18
50
37
K60
1105711
25
18
50
37
K99
1105710
25
18
50
37
5.7L (Carb.)
K68
1105720
25
18
47
35
6.2L (Diesel)
K81
1105632
27
20
43
32
5.7L (Carb.
and (TBI)
K68
1105720
25
18
47
35
K99
1105718
25
18
47
35
6.2L (Diesel)
K09
1101215
27
20
43
32
K81
1105632
27
20
43
32
7.4L (Carb.)
K68
1105661
25
18
50
37
4.8L (Carb.)
K81
1100207
25
18
24
17
Engine
RV
4.3L (TBI)
5.0L (TBI)
5.7L (TBI)
6.2L (Diesel)
7.4L (TBI)
G Van
4.3L (TBI)
5.0L (TBI)
5.7L (TBI)
P Truck
Mounting Torque
Bottom Bracket Bolt
Top Bracket Bolt
N-m
Ft. Lbs.
Nm
Ft. Lbs.
SPECIFICATIO NS (CONT.)
STARTER SPECIFICATIONS
No Load Test @ 10 Volts
Truck
Model
Engine
Application
Part No.
Starter
Series
Type
AM PS
M inim um
M axim um
M inim um
RPM
M axim um
R.V.G.P
6.2 L Diesel
1113589
27MT
136
120
210
9000
13400
6.2L Diesel
1113590
27MT
136
120
210
9000
13400
4.3 L (Carb.)
1998559
10MT
101
60
90
6500
10500
5.0L (TBI), 5.7L (TBI)
1998560
10MT
101
70
110
6500
10700
R,V,G
5.0L (TBI), 5.7L (TBI)
1998561
10MT
101
70
110
6500
10700
5.7L (TBI)
1998561
10MT
101
70
110
6500
10700
R,V
4.3L (TBI), 5.0L (TBI),

5.7L (TBI), 7.4L (TBI)
1998562
10MT
101
70
110
6500
11070
4.3L (TBI), 5.0L (TBI),

5.7L (TBI), 5.7L (Carb.)
1998562 *
10MT
101
70
110
6500
11070
7.4L (Carb.), 5.7L (Carb.), 5.7L (TBI)
1998562
10MT
101
70
110
6500
11070
4.3L (TBI), 5.0L (TBI),

7.4L (TBI), 5.7L (TBI),
1998565
10MT
101
70
110
6500
10700
5.7L (Carb.)
1998565
10MT
101
70
110
6500
10700
STARTER SHIMS
Gas Engines
Diesel Engines
Shim
Part No.
Shim
Part No.
0.38 m m (0.015-inch)
1246249
1.0 mm (0.04-inch)
23500396
1.0 mm
14036090
2 .0 mm (0.08-inch )
23500397
(0.04-inch )
TORQUE VALUES
Battery R etainer..........................................................................................................................................
Top Bar of Hold-Down:
Side Terminal B a tte rie s .....................................................................................................................
Top Terminal B atteries.......................................................................................................................
Battery Terminals:
Top Term inals........................................................................................................................................
Side T e rm in a ls .....................................................................................................................................
Glow Plug Controller Upper N u ts .........................................................................................................
Glow Plug Temperature S w itch .............................................................................................................
Glow Plugs...................................................................................................................................................
Diesel Engine Starter Mounts:
Through B olt..........................................................................................................................................
N u t ...........................................................................................................................................................
B o lt...........................................................................................................................................................
Gas Engine Starter Mounting B olts......................................................................................................
Engine Block Heater S cre w .....................................................................................................................
N-m
Ft. Lbs.
17
13
3.5
6.8
In. Lbs.
30
60
17
15
5.0
23
17
13
11
38
10
32
38
1.8
28
48
17
12
90
24
28
16
SPEC IA L TOOLS
6E-1
SECTION 6E
EMISSIONS
CONTENTS
SUBJECT
PAGE
Drivability and Emissions - C a rb urete d ................................................................................................................. 6E8- 1

Orivability and Emissions - Diesel........................................................................................................................... 6E9- 1
For information on vehicles with Throttle Body Injection (TBI), refer to the Fuel and Emissions Service Manual.
6E8-1
SECTION 6E8
DRIVEABILITY AND EMISSIONS

CARBURETED
This section applies to:
4.8 L L25 ENGINE CODE T
5.7 L LT9 ENGINE CODE M
7.4 L LE8 ENGINE CODE W
CO NTENTS
SUBJECT
PAGE
General In fo rm a tio n ................................................................................................................................................. 6E8- 2

D riv e a b ility ............................................................................................................................................................6E8- 2
E m is s io n s .................................................... ..........................................................................................................6E8- 2
Maintenance S chedule........................................................................................................................................ 6E8- 2
Vehicle Emission Control Inform ation L a b e l................................................................................................. 6E8- 2
Visual Underhood In s p e c tio n ........................................................................................................................... 6E8- 2
In tr o d u c tio n .............................................................................................................................................................. 6E8- 4
General D e s c rip tio n .............................................................................................................................................6E8- 4
Component L o c a tio n ...........................................................................................................................................6E8- 5
D riveability S ym ptom s.............................................................................................................................................6E8- 8
W ont Start Engine Cranks O K .....................................................................................................................6E8- 8
Hard Start C old................................................................................................................................................. 6E8- 9
Hard Start H o t .......................................................................................................... ...................................... 6E8- 9
Stall A fter Start C o ld ...................................................................................................................................... 6E8-10
Stall A fter Start H o t........................................................................................................................................ 6E8-10
Hesitation/Sag, S tu m b le .................................................................................................................................... 6E8-10
Surges and/or C h u g g le ...................................................................................................................................... 6E8-11
Lack of Power, Sluggish or S p o n g y.................................................................................................................6E8-11
B a c k fire .................................................................................................................................................................. 6E8-12
Misses/Cuts O u t ................................................................................................................................................... 6E8-12
Rough, Unstable or Incorrect Idle, S ta llin g ....................................................................................................6E8-13
W ont I d l e ..............................................................................................................................................................6E8-13
Poor Fuel E c o n o m y .............................................................................................................................................6E8-13
Dieseling, Run O n................................................................................................................................................. 6E8-14
Detonation/Spark K n o c k .................................................................................................................................... 6E8-14
Excessive Exhaust Emissions (O d o rs )............................................................................................................ 6E8-14
Restricted Exhaust C h e c k ..................................................................................................................................6E8-15
Evaporative Emission Control System (E E C S )................................................................................................. 6E8-16
General D e s c rip tio n .............................................................................................................................................6E8-16
Diagnosis of E EC S...............................................................................................................................................6E8-17
On-Vehicle Service E E C S ..............................................................................................................................6E8-18
A ir Injection Reaction (AIR) S ystem .....................................................................................................................6E8-19
Diagnosis of A IR ................................................................................................................................................... 6E8-20
On-Vehicle Service A IR ..................................................................................................................................6E8-21
Exhaust Gas Recirculation (EGR) S y s te m ..........................................................................................................6E8-32
Diagnosis of E G R ................................................................................................................................................. 6E8-33
On-Vehicle Service E G R ................................................................................................................................6E8-33
6E8-2 DRIVEABILITY AND EMISSIONS CARBURETED

CONTENTS (CONT.)
SUBJECT
PAGE
Early Fuel Evaporation System (EFE)...................................................................................................................6E8-35

Diagnosis o f E F E ................................................................................................................................................. 6E8-35
On-Vehicle Service EFE.................................................................................................................................. 6E8-36
Positive Crankcase V entilation (P C V ).................................................................................................................6E8-39
Diagnosis of P C V ................................................................................................................................................. 6E8-39
On-Vehicle Service P C V ................................................................................................................................6E8-39
Therm ostatic A ir Cleaner (THERMAC).................................................................................................................6E8-40
Diagnosis o f THERM AC...................................................................................................................................... 6E8-41
On-Vehicle Service THERM AC..................................................................................................................... 6E8-42
Throttle Return Control (TRC) S ystem .................................................................................................................6E8-43
Diagnosis of T R C ............. ................................................................................................................................... 6E8-43
On-Vehicle Service T R C ................................................................................................................................6E8-44
G EN ERA L INFORMATION
DRIVEABILITY
The driveability diagnosis procedures apply to various
systems in current GM vehicles. The procedures assume
that the vehicle worked right at one time and the problem
is due to time, wear, dirt or other causes. Start with the
introduction that follows. This will describe a systematic
diagnostic procedure.
Any system disconnected during diagnosis should be
reconnected. This includes wires, hoses, linkage, etc.
When removing air cleaner, plug hose fittings that could
cause an air leak.
EMISSIONS
The exhaust emission control systems used on General
Motors engines perform a specific function to lower
exhaust emissions while maintaining good fuel economy
and driveability.
MAINTENANCE SCHEDULE
Refer to the General Motors Maintenance Schedule in
Section OB of this Service Manual for the maintenance
service that should be perform ed to retain emission
control performance.
VEHICLE EMISSION CONTROL

INFORMATION LABEL
The Vehicle Emissions Control Information label (Fig. 1)
contains important emission specifications and setting
procedures. In the upper left corner is exhaust emission
information which identifies the year, the manufacturing
division of the engine, the displacem ent in liters of the
engine, the class of vehicle and type of fuel metering.
Also there is an illustrated em ission com ponent and
vacuum hose schematic. This label is located in the
engine compartment of every General Motors Corporation
vehicle. If the label has been removed, it can be ordered
from the parts division. (WDDGM)
VISUAL/PHYSICAL UNDERHOOD
INSPECTION
One of the most important checks that must be done as
p a rt o f a n y d ia g n o s tic p ro c e d u re is a c a re fu l
visual/physical underhood inspection. This can often lead
to fixing a problem without further steps. Inspect all
vacuum hoses for correct routing, pinches, cuts, or
disconnects. Be sure to inspect hoses that are difficult to
see beneath the air cleaner, compressor, generator, etc.
Inspect all the wires in the engine com partm ent for
correct and good connections, burned or chaffed spots,
pinched wires, or contact with sharp edges or hot exhaust
m a n ifo ld s . T h is v is u a l/p h y s ic a l in s p e c tio n is ve ry
important. It must be done carefully and thoroughly.
DRIVEABILITY AND EMISSIONS CARBURETED 6E8-3
ADJUSTM ENT
PROCEDURE
ENGINE ADJUSTMENT
SPECIFICATIONS
LABEL CODE
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC
LABEL PART NUMBER
AREA OF CERTIFICATION
"ALW AYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL

FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS".
E X H A U S T E M IS S IO N S Y S T E M
HGM07.4 AG A 4
7S-3218
Figure 1Vehicle Emission Control Information Label

ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVIRONMENTAL PROTEC
TION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE REGULATIONS FOR THE CONTROL OF AIR
POLLUTION FROM NEW MOTOR VEHICLES. THIS CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS
BEING SET TO FACTORY STANDARDS. IN MOST CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE TO PREVENT INDISCRIMINATE OR ROUTINE ADJUST
MENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR TEMPORARILY REMOVING PLUGS,
CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT, MUST BE STRICTLY FOLLOWED AND, WHEREVER
PRACTICABLE, RETURNED TO THE ORIGINAL INTENT OF THE DESIGN.
INTRODUCTION
GENERAL DESCRIPTION
The engine has controls to reduce exhaust emissions
while m aintaining good driveability and fuel economy.
The following emission controls are on all engines:
Positive Crankcase Ventilation (PCV)
Exhaust Gas Recirculation (EGR)
Therm ostatic Air Cleaner (THERMAC)
Air Injection Reaction (AIR)
Early Fuel Evaporation (EFE)
Evaporative Emission Control (EECS)
Throttle Return Control (TRC)
Deceleration Control
Positive Crankcase Ventilation (PCV)

All engines have closed Positive Crankcase Ventilation
S ystem to p ro v id e m ore co m p le te s c a v e n g in g of
crankcase vapors.
Ventilation air is drawn from the dirty air side of the air
cleaner, through a hose, down into the crankcase, up
through the ventilator valve, through a hose and into the
intake manifold. Intake manifold vacuum draws any fumes
from the crankcase to be burned in the engine.
EXHAUST GAS RECIRCULATION (EGR)

The Exhaust Gas Recirculation system is used on all
engines. It meters exhaust gas into the induction system
for recirculation through the combustion cycle to reduce
oxides of nitrogen emissions. v
The EGR valve rem ains closed during periods of
engine idle and deceleration to prevent rough idle from
excessive exhaust gas d ilu tio n in the idle a ir/fu e l
mixtures. It also remains closed at wide open throttle to
prevent power loss.
Thermostatic Air Cleaner (THERMAC)

The Therm ostatic Air Cleaner is designed to keep air
entering the carburetor at approximately 100F. Keeping
the air at 100F, or more, improves engine warm-up
driveability, and will help m inimize carburetor icing.
Air Injection Reaction (AIR)

The Air Injection Reaction system provides additional
oxygen to the exhaust gases to continue the combustion
process.
EARLY FUEL EVAPORATION (EFE)

The EFE system is used to provide a source of rapid
h eat to th e e n g in e in d u c tio n syste m d u rin g co ld
driveaway. Rapid heating is desirable because it provides
fo r q u ic k fu e l e v a p o ra tio n and m ore u n ifo rm fu el
distribution to aid cold driveability.
Evaporative Emission Control

This system has a canister which stores fuel vapor from
the fuel tank and the carburetor. The fuel vapor is
removed from the canister and consumed in the normal
combustion process when the engine is running.
Throttle Return Control (TRC)

The Throttle Return Control system helps to prevent an
over-rich condition on deceleration. The vacuum operated
Throttle Kicker will not allow the throttle to close fully until
the engine speed falls below a specified RPM. By holding
the throttle open slightly, more air is allowed to enter the
engine to maintain a more efficient air/fuel ratio.
Deceleration Control
The deceleration control uses a deceleration valve to
control emissions and back-fire on deceleration. When
deceleration causes a sudden rise in manifold vacuum,
the deceleration valve will open to adm it fresh air to the
inlet manifold. After a calibrated tim e delay, the valve will
c lo s e . T h e s y s te m is m a in ly u s e d w ith m a n u a l
transmission equipped vehicles.
'G'series
rpo:LT9
v in c o d e :M
5.7L
V8 4BBL
Heavy Duty
EM IS S IO N S D E V IC ES
1
Crankcase vent valve (PCV)
2 Air injection pump

2a Air injection divert valve
3
Deceleration valve
EFE valve
6 Fuse panel
17 Fuel vapor canister
17a Fuel vapor canister solenoid
19 Throttle return control
20 Throttle valve relay
Exhaust Gas Recirculation valve
5S-2149
Figure 2Component Locations 5.7 L (G-Series)
SERIES
r p o :LT9
v in c o d e
:M
5.7 L V 8
4BBL
Heavy Duty
...I EMISSIONS DEVICES

1
2

Air injection pump

3
Deceleration valve
EFE valve
Fuse panel
17 Fuel vapor canister solenoid

21
Engine speed relay

5S-2150
Figure 3Component Locations 5.7 L (P-Series)
DRIVEABILITY AND EMISSIONS -
'P' SERIES
rpo
:LE 8
v in c o d e
CARBURETED 6E8-7
:W
7.4L
V8
4BBL
Heavy Duty
ii>:
19 *
2a 2
IT
f
k_J
EMISSIONS DEVICES
1
Air injection pump

3 Deceleration valve
4
EFE valve
6 Fuse panel
17 Fuel vapor canister
5S-2152
Figure 4Component Locations 7.4 L (P-Series)
DRIVEABILITY SYMPTOMS
BEFORE STARTING
VISUAL CHECK
Verify the custom er com plaint, and locate the correct

symptom below. Check the items indicated under that
symptom.
If the ENGINE CRANKS BUT WILL NOT RUN, see No
Start Engine Cranks O K below.
Several of the symptom procedures below call for a

careful visual check. This check should include:
V a cu u m h o s e s fo r s p lits , k in ks, and p ro p e r
c o n n e c tio n s , as sh ow n on E m is s io n C o n tro l
Information label.
A ir le a ks at c a rb u re to r m o u n tin g and in ta k e
manifold.
Ignition wires for cracking, hardness, proper routing,
and carbon tracking.
W iring for proper connections, pinches, and cuts.
DISTRIBUTOR INFORMATION
Refer to Section 6 D, Engine Electrical, for Ignition
System including distributor information.
CARBURETOR ADJUSTMENT
Carburetor adjustment and specifications can be found
in Section 6 C 1, Carburetors.
Theimportanceof this step cannot bestressedtoo

stronglyit canleadtocorrectingaproblemwithout
furtherchecksandcansavevaluabletime.
WONT START ENGINE CRANKS OK

Definition: Engine cranks OK, but does not start. May fire a few times.
Make sure proper starting procedure is being used.
See O w ners Manual.
Visual check:
Vacuum hoses for splits, kinks and proper con
nections, as shown on Vehicle Emission Con
trol Information label.
Ignition w ires fo r cracking, hardness and
proper connections at both distributor cap and
spark plugs.
Remove air cleaner:
C h e c k c a rb u re to r ch o ke v a lve , va c u u m
break(s), linkage and unloader operation. See
Section 6 C. Set to specifications. Choke valve
should move sm oothly and be closed when
cold, and open when hot.
Check for presence of fuel by noting carburetor ac
celerator pum p operation. Look for gas squirt in car
buretor bore while quickly opening throttle lever.
If no pump squirt:
Check for fuel in tank.
Check carburetor fuel inlet filter. Replace
if dirty or plugged.
Check fuel pump capacity.

If fuel pump checks OK, check float nee
dle for sticking in seat, or binding float.
If there is a pump squirt:
Crank engine and check for flooding.
If not flooding, see Ignition System Di
agnosis, Section 6 D.
Remove spark plugs. Check for wet plugs, cracks,
wear, im proper gap, burned electrodes, or heavy de
posits. Repair or replace as necessary.
Visually check distributor cap inside and out for
moisture, dust, cracks, burns, and arcing to coil
m ounting screws.
Try to turn distributor shaft by hand. Drive pin may
be broken.
Very cold temperatures:
Check that the proper viscosity oil is being
used, and crank case oil is not contaminated
with gasoline.
HARD START COLD

Definition: Engine cranks OK, but does not start for a long time. Does eventually run. If the engine starts but imm ediately
dies (as soon as key is released from start position), see No Start, Engine Cranks O K symptom.
Make sure driver is using correct starting procedure.
See Ow ners Manual.
Visual check:
Air leaks at carburetor m ounting and intake
manifold.
Ignition wires for cracking, hardness, and
proper connections, at both the distributor cap
and spark plugs.
W iring for proper connections, pinches and
cuts.
Check the choke valve, throttle and fast idle cam for
s tic k in g . R eplace any m a lfu n ctio n in g parts. If
caused by foreign material and gum, clean with suit
able non-oil base solvent. See Section 6 C.
Check choke and vacuum break operation and ad
justm ent. Choke should be closed cold. See Section
6 C.
Check EGR system for sticky operation that could
cause valve to stick open.
Check float level using external float gage. Adjust

float to specification if required. See Section 6 C.
Check carburetor fuel inlet filter. Replace if dirty or
plugged.
Check ignition system see Section 6 D. Check
distributor for:
Worn shaft.
Bare and shorted wires.
Pick-up coil resistance and connections.
Loose ignition coil ground.
Moisture in distributor cap.
Remove spark plugs; check for wet plugs, wear, im
proper gap, burned electrodes or heavy deposits.
Check ignition tim ing per Vehicle Emission Control
Information label.
Verify proper engine oil viscosity per recomm enda
tions in M aintenance Schedule.
Check fuel pump volume, pressure and vacuum.
HARD START HOT

Definition: Engine cranks OK, but does not start for a long time. Does eventually run. If the engine starts but imm ediately
dies (as soon as key is released from start position), see Ignition System Diagnosis, Section 6 D.
Visual (physical) check:
Vacuum hoses for splits, kinks, and proper
connections, as shown on Vehicle Emission
proper connections, at the distributor cap and
s p a r k p lu g s .

cuts.
Make sure driver is using correct starting procedure.
See O w ners Manual.
Check choke valve, throttle linkage and fast idle cam
for sticking.
Check choke and vacuum break operation and ad
justm ent. Choke should be open hot. See Section
6 C.
Check for carburetor flooding.
Check fuel inlet filter. If plugged replace.
Check float level using external float gage. Adjust
float to proper specification if required. See Section
6C.
Check fuel pump volume, pressure and vacuum.
Check fuel line routing.
Check EFE valve. EFE valve should be open.

Check EGR for sticky operation that could cause
valve to stick open.
Check for obvious overheating problems:
Low coolant.
Loose water pump belt.
Restricted air flow to radiator, or restricted
water flow through radiator.
Check ignition system, Section 6 D. Check distribu
tor for:
Worn shaft.
Bare and shorted wires.
Interm ittent pickup coil or connections, mod
ule, ignition coil ground and condenser. Repair
or replace as necessary.
Remove spark plugs. Check for cracks, wear, im
proper gap, burned electrodes, heavy deposits. Re
pair or replace as necessary.
Check ignition tim ing. See Vehicle Emission Control
Information label.
STALL AFTER START COLD

Definition: Engine at room or outside temperature, within three minutes after start. ( 1 ) Stalls after brief idle; (2) dies as
soon as any load is placed on engine (such as A/C turned O N or transmission engaged); or (3) Dies on initial driveaway.
If symptom is present cold and hot, go to symptom
Stall After Start H ot.
Make sure hot air tube is connected to air
cleaner.
Check proper operation of THERMAC.
Check carburetor choke valve, throttle linkage
and fast idle cam for sticking.
With engine running, visually check vacuum
break linkage for movement while removing
and re-installing vacuum hoses to vacuum
breaks. If the linkage does not move and vac
uum is at hose, check for binding linkage. If
linkage OK, replace vacuum break unit.
With engine OFF, check all choke adjust

ments, including vacuum breaks and TVS if
used. See Section 6 C.
Check fast idle speed setting and curb idle
speed.
Check carburetor accelerator pump operation.
Check EFE valve for proper operation. EFE
valve should be closed cold. See Chart C-9C.
Check EGR valve for proper operation. See
Chart C-7C.
Check engine tim ing. See Vehicle Emission
Poor or c o n ta m in a te d g a s o lin e . S u g g e st
owner try different brand.
STALL AFTER START HOT

Definition: The engine starts OK, but (1) dies after brief idle; (2) dies as soon as any load is placed on engine (such as A/C
turned O N or transmission engaged); (3) dies on initial driveaway.
Make sure hot air tube is connected to air cleaner.
Check proper operation of THERMAC.
Check carburetor choke and vacuum breaks for
proper operation. See Section 6 C for check proce
dure.
Check float level using external float gage. See Sec
tion 6 C.
Check carburetor accelerator pum p operation.

Check EGR valve for proper operation Chart C7C.
Check for overcharged A/C System.
Check for obvious overheating problems:
Low coolant.
Restricted air flow to radiator or restricted
HESITATION/SAG, STUMBLE
Definition: Momentary lack of response as the accelerator is pushed down. Can occur at all vehicle speeds. Usually most
severe when first trying to make vehicle move, as from a stop sign. May cause the engine to stall if severe enough.
proper connections, at both distributor and
spark plugs.
cuts.
Check proper operation of THERMAC. See diagno
sis of THERMAC.
Note: Cold engine only check the following for
sticking or faulty operation:
Carburetor choke, including vacuum breaks,
throttle linkage and fast idle cam.
Check all choke adjustments, including vac
uum breaks.

tion 6 C.
Check EGR valve operation Chart C-7C.
Check canister purge system for proper operation.
See Evaporative Emission Control System Diagno
sis.
Check for open ignition coil ground and for interm it
tent ECM ground.
Check engine tim ing. See Vehicle Emission Control
Information label.
Poor or contaminated gasoline. Try a different brand
of gasoline.
SURGES AND/OR CHUGGLE

Definition: Engine power variation under steady throttle or cruise. Feels like the car speeds up and slows down with no
change in the accelerator pedal.
proper connections, at both distributor and
spark plugs.
cuts.
Have driver read explanation of transmission con
verter clutch and A/C compressor operation in Own
e rs Manual.
sis of THERMAC.
Check for intermittent open, or short to ground in
TCC circuit.
Check for proper operation of EGR. See Chart C-7C.
Check carburetor fuel inlet filter, replace if dirty or

plugged.
Check carburetor float level using external float
gage. See Section 6 C.
Test fuel pump capacity. See Section 6 C.
Remove spark plugs, check for cracks, wear, im
Check condition of distributor cap, rotor and spark
plug wires.
Check for arcing to coil attaching screws in distribu
tor cap.
Check for interm ittent ground connection on integral
ignition coil.
Poor or contam inated gasoline. Try a different brand
of gasoline.
LACK OF POWER, SLUGGISH OR SPONGY

Definition: Engine delivers less than expected power, little or no increase in speed when accelerator pedal is pushed down
part way.
Visual check:
Ig nitio n w ire s fo r cra ckin g , harness, and
proper connections, at both the distributor cap
and spark plugs.
cuts.
Compare custom ers vehicle to sim ilar unit. Make
sure the custom ers vehicle has an actual problem.
Was the custom ers old vehicle much more power
ful?
Remove air cleaner and check air filter for dirt.
Check for proper operation of THERMAC. See diag
nosis of THERMAC.
Check for full throttle valve opening in carburetor by
depressing accelerator pedal to floor.
gage.
Check for proper operation of carburetor air valve.
See Section 6 C.
Information label.
Check transmission for proper downshift and TCC
operation.
Check EGR operation. See Chart C-7C.

Check EFE Valve.
proper gap, burned electrodes, heavy deposits. Re
pair or replace as necessary.
Check for an exhaust system restriction:
1 . With engine at normal operating temperature,
connect a vacuum gage to any convenient
vacuum port on intake manifold.
2. Run engine at 1000 rpm and record vacuum
reading.
3. Increase rpm slowly to 2500 rpm. Note vac
uum reading at steady 2500 rpm.
4. If vacuum at steady 2500 rpm is more than 3
inches lower than 1000 rpm, exhaust system
sh ou ld be insp ected fo r re s trictio n s. See
Chart B-1 .
Check engine valve tim ing and compression.
Check engine for proper or worn camshaft, see Sec
tion 6 A.
Poor or contaminated fuel. Try a different brand of
gasoline.
BACKFIRE
Definition: Fuel ignites in intake manifold, or exhaust system, making a loud popping noise.
Visual check:
Ignition wires for cracking or hardness proper
connection, at both the distributor cap and
spark plugs.
Chaffed wiring harness by pulleys or metal
edges.
sis of THERMAC.
Note: Cold engine only check the following for
sticking or faulty operation:
C arburetor choke, including vacuum break
and throttle linkage.
Check EFE Valve.
Check for proper operation of EGR valve.

Perform a compression check look for sticking or
leaking valves.
Check for restricted exhaust system. See Chart B-1.
Check output voltage of ignition coil. See Ignition
System Diagnosis, Section 6 D.
C h e c k o p e ra tio n of d e c e l (g u lp ) va lve if so
equipped.
Check for crossfire between spark plugs, distributor
cap, spark plug wires and proper routing of plug
wires. W ires for cylinders which fire in sequence on
the same side of the engine should not be routed
next to each other; i.e., 8 and 4, and 5 and 7. See
Section 6 D.
Check for intermittent condition in ignition system.
Pick-up coil.
Ignition coil ground on integral coil.
Ignition coil prim ary connections.
Check for proper valve tim ing.
MISSES (CUTS OUT)

Definition: Pulsation or jerking that follows engine speed, usually more pronounced as engine load increases. The
exhaust may have a steady spitting sound at idle or low speed. Not normally felt above 1500 rpm or 30 rpm (48 km/h).
Ignition w ires for cracking, hardness and
proper connections at both distributor cap and
spark plugs.
cuts.
Check spark plug wire routing for correct firing or
der.
Check for m isfiring at spark plugs:
1. Disconnect and plug air cleaner and EGR vac
uum hoses.
2. Check spark at all plug wires with J26792 (ST125).
If there is no spark on any cylinder, see
Ignition System D iagnosis, Section
6 D.
Spark at all cylinders.
Visually check distributor cap inside and out for
moisture, dust, cracks, burns and check for coil
arcing to mounting screws. With engine running,
spray cap and plug wires with fine water mist to
check for shorts.
Check for poor ground on integral ignition coil.

Check EGR valve for sticking partially open.
Remove spark plugs and check for cracks, wear, im
proper cap, burned electrodes and heavy deposits.
Check pickup coil in distributor with ohmmeter, and
check for proper connections at module. Pickup coil
should be 500-1500 ohms and not grounded. See
Sec. 6 D.
If pickup coil checks OK,
Check for ignition dwell increase from

low to high rpm by connecting dwell me
ter to d istributor TACH term inal. If
dwell doesnt increase, replace ECM.
Remove rocker covers, check for bent pushrods,
worn rocker arms, broken valve springs, worn cam
shaft lobes. Repair as necessary. See Section 6 A.
ROUGH, UNSTABLE OR INCORRECT IDLE; STALLING

Definition: The engine runs unevenly at idle. If bad enough, the car may shake. Also, the idle speed may vary (called
hunting ). Either condition may be bad enough to cause stalling. Engine idles at incorrect speed.
nections as shown on Vehicle Emission Con
Ignition wires for cracking, hardness, or proper
connections, at both distributor cap and spark
plugs.
Check throttle linkage for sticking or binding.
Check carburetor for flooding.
tion 6 C.
Check engine idle speed. See Vehicle Emission
Check EGR System. See Chart C-7C. There should
be no EGR at idle.
If rough idle occurs hot, perform these additional

checks:
Check PCV valve for proper operation by plac
ing finger over inlet hole in valve end several
times. Valve should snap back. If not, replace
valve.
Check canister purge and bowl vent control
system. See Evaporative Emission C ontrol
System Diagnosis.
Remove carbon with top engine cleaner. Fol
low instructions on can.
Check for proper spark plug gap.
Run a cylinder compression check. See Sec
tion 6 .
Information label.
Check for exhaust system restriction. See Chart B-1 .
WONT IDLE
Definition: Engine starts OK, but dies at idle. Will run if accelerator pedal is held at part throttle.
Air leaks at carburetor m ounting and intake
manifold.
Check for carburetor flooding. See Section 6 C.
Check EGR system. See Chart C-7C. Check for a

loose valve or sticking EGR plunger. If sticking oper
ation is found, clean or replace valve. There should
be no EGR at idle. It may be necessary to remove
the valve to check for leaking.
Check engine idle speed. See Vehicle Emission
Check carburetor idle adjustment. If unable to ad
just, check carburetor idle system. See Section 6 C.
Check spark plug condition and gap.
Check for exhaust system restriction. See Chart B1.
POOR FUEL ECONOMY

Definition: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy is
noticeably lower than it was on this car at one time, as previously shown by an actual road test.
Check owners driving habits.
Is A/C on full tim e (defroster mode on)?
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Suggest driver read Im portant Facts on Fuel
Econom y in O w ners Manual.
Check air cleaner dam per door operation (THERMAC).
Check air cleaner element (filter) for dirt or being
plugged.
Check for proper calibration of speedometer.
Visual check:
Ignition w ires for cracking, hardness and

proper connections.
Information label.
Check compression. See Section 6 A.
Check TCC for proper operation.
Check for dragging brakes.
Suggest owner fill fuel tank and recheck fuel econ
omy.
Check for exhaust system restriction. See Chart B-1 .
DIESELING, RUN-ON
Definition: Engine continues to run after key is turned OFF, but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.
Visual check:
Carburetor choke, throttle linkage and fast idle
cam for sticking.
Check carburetor choke, vacuum break linkage,
throttle linkage and fast idle cam for proper adjust
ment. See Section 6 C.
Check cruise control for proper adjustment.
Check engine idle speed.
Check ignition timing. See Vehicle Emission Control

Information label.
Remove carbon with top engine cleaner. Follow in
structions on can.
Check for engine overheating. Normal coolant tem
perature is 8 5 C -1 0 0 C (185F-215F).
Low coolant.
Loose vfater pump belt.
Inoperative fan clutch.
DETONATION/SPARK KNOCK
Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp m etallic knocks that change
with throttle opening. Sounds like popcorn popping.
Check EGR System for proper operation. See Chart
C-7C.
Information label.
Check for obvious overheating problems. 8 5 C 100C (185C -215F) is normal.
Low coolant.
Inoperative fan clutch.
Check for air leaks at carburetor mounting and in

take manifold.
Check for poor fuel quality, proper octane rating.
Remove carbon with top engine cleaner. Follow in
structions on can.
If excessive carbon in cylinders, check for leaking
valve seals.
Check for improper operation of transmission (i.e.,
linkage adjustment) and TCC.
Check for incorrect basic engine parts, such as
cam, heads, pistons, etc.
EXCESSIVE EXHAUST EMISSIONS (ODORS)

Definition: Car fails an emission test. May also have excessive rotten egg smell (hydrogen sulfide).
If test shows excessive CO and HC (also has exces
sive odors):
Remove air cleaner and check air filter

for dirt or being plugged. Replace as
necessary.
Check operation of air m anagem ent sys

tem. See appropriate C-6 HD Chart in Air
Injection Reaction section.
Check carburetor for flooding.
Check float level using external float
Check canister for loading and check
purge system for proper operation. See
Evaporative Emission Control System Di
agnosis.
Check for incorrect idle speed.
C heck for m isadjusted idle m ixture if

plugs are removed.
Check for incorrect tim ing. See Vehicle

Check choke valve and linkage for stick

ing of faulty operation.
Check condition of spark plugs, plug

wires and distributor cap.
If test shows excessive NOx:
Check items which cause car to run rich.

Make sure engine is at normal operating
temperature.
Visually check hoses for splits, kinks and
proper connections, as shown on Vehi
cle Emission Control Information label.
Check choke, vacuum breaks and fast

idle adjustments.
Check for stuck PCV valve or obstructed
hose.
Check for lead contamination of catalytic
converter. Check for absence of filler
neck restrictor.
Check items which cause vehicle to run lean,

or to run too hot.
Check EGR valve for not opening. See
Chart C-7C in Section C.
Check for vacuum leaks.
Check for inoperative THERMAC.

Check ignition tim ing for excessive base
advance. See Vehicle Emission Control
Information label.
Check coolant system and cooling fan

for proper operation.
Remove carbon with top engine cleaner.
Follow instructions on can.
Proper diagnosis for a restricted exhaust system is essential before any components are
replaced. The following diagnostic procedure is recommended:
1. Remove the rubber hose at the
exhaust manifold A.I.R. pipe check
valve. Remove check valve.
2. Connect a fuel pump pressure gage
to a hose and nipple from a Propane
Enrichment Device (J26911) (see
illustration).
3. Insert the nipple into the exhaust
manifold A.I.R. pipe.
4. With the engine at normal operating
temperature and running at 2500
rpm, observe the exhaust system
backpressure reading on the gage.
5. If the backpressure exceeds 2 3/4
psi, 19 kPa a restricted exhaust
system is indicated.
6. Inspect the entire exhaust system
for a collapsed pipe, heat distress,
or possible internal muffler failure.
7. If there are no obvious reasons for
the excessive backpressure, a
restricted catalytic converter
should be suspected, and replaced
using current recommended
procedures.
[ T ] fuel
pump pr essur e g a u g e
[ T ] hose
a n d n ip p l e f r o m p r o p a n e e n r ic h
ment
DEVICE (J-26911)
4S-1168
Chart B-1Restricted Exhaust System Check
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)
Figure 5Evaporative Emissions System
GENERAL DESCRIPTION
PURPOSE
The Evaporative Em ission C ontrol System (EECS)
(Figure 5) limits fuel vapor into the atmosphere. The
system traps fuel vapor from the fuel tank and carburetor
float bowl into a fuel vapor canister. The fuel tank has a
non-vented fuel cap and a single vent pipe to the canister.
The canister absorbs and stores the fuel vapor in a
carbon element until it can be removed and burned
during the normal com bustion process. When the engine
is running, a therm ostatic vacuum switch determines
when the fuel vapor is purged into the intake air flow.
OPERATION (Figure 5)
This system uses the following control valves:
Purge control valve mounted on the canister.
Vapor vent valve mounted on the canister.
A therm al bowl vent valve (some applications).
A therm ostatic vacuum switch (TVS) installed in the
in ta k e m a n ifo ld to s e n s e e n g in e c o o la n t
temperature.
When the engine is shut off, manifold vacuum is lost at
the vapor vent valve. The spring loaded valve in the vapor
vent valve now connects the carburetor bowl vent to the
canister. Carburetor float cham ber vapors now pass into
the canister for storage. When the engine is restarted,
manifold vacuum draws the vapor vent controlling valve
against spring pressure, closing off the bowl vent. Ported
vacuum from the carburetor is connected to the TVS.

When the TVS opens, ported vacuum opens the purge
control valve. When the valve opens, manifold vacuum
draws vapors from the canister into the intake manifold.
The therm al bowl vent valve (TBVV) is located in the
section of hose that connects the carburetor bowl vent
fitting to the canister control valve.
The TBVV will close and prevent vapor movement at
3 2 C (90F) and below. The TBVV will open at 49C
(120F) to permit vapor flow to the canister control valve.
FUEL VAPOR CANISTER, PRIMARY (Figure 6)

The basic large size, two cham ber closed bottom
canister is used on all systems and operates as follows:
Gasoline vapors from the fuel tank flow into the tube
labeled Fuel Tank, and vapors from the carburetor float
bowl flow into the tube labeled CARB BO W L, and are
absorbed by the carbon. The canister is purged when the
engine is running above idle speed. The closed bottom
design keeps water from entering the bottom of the
canister, freezing, and restricting purge air flow. During
purge, air is drawn from the clean side of the air cleaner,
to the tube on the canister labeled AIR C LN R , through
the carbon and into the intake manifold to be burned.
Some closed bottom canisters draw purge air directly
from the atmosphere.
LARGE SIZE TWO CHAMBER

CLOSED BOTTOM CANISTER
l 2 j VAPOR VENT CONTROL VALVE

H I PURGE CONTROL VALVE
H H CLEAN AIR TUBE
"A IR CLNR"
m
VAPOR FROM FUEL TANK
[ 6 | VAPOR FROM BOWL VENT

[ T ] TO MANIFOLD VACUUM SIGNAL
[~8~! TO PORTED VACUUM
[~9~i VAPOR TO PURGE LINE
fTp"; FILTER
j j j j CARBON
f l T i BOTTOM COVER
f l 3 ] DUST CAP
O f ] AIR FLOW
5S-1659
Figure 6Fuel Vapor Canister

CANISTER PURGE CONTROL VALVE (Figure 6)
The Canister Purge Control Valve is a spring-biased
d ia p h ra g m valve, norm a lly close d, w hich allow s or
prevents purging of the canister. When the engine is off or
idling, the spring holds the valve closed, preventing
canister purge. When the engine is off-idle, however,
tim ed manifold vacuum pulls the diaphgram upward,
opening the valve and allowing the canister to be purged.
DIAGNOSIS OF EECS
SYSTEM DIAGNOSIS
Poor idle, stalling and poor driveability can be
caused by:
Inoperative vapor vent valve.
Inoperative purge control valve.
Damaged canister.
Hoses split, cracked and, or, not connected to
the proper tubes.
VAPOR VENT CONTROL VALVE (Figure 6)

The vapor vent control valve prevents venting of the
c a rb u re to r flo a t bow l d u rin g e n g in e o p e ra tio n . A
spring-biased diaphragm valve, normally open, allows (or
prevents) fuel vapors from the float bowl to enter the
canister. When the engine is off, spring tension holds the
valve open, allowing normal venting.
W hen the engine is turned on, however, m anifold
vacuum pulls the diaphragm up to close the valve.
FUEL VAPOR CANISTER, AUXILIARY (Figure 7)

An Auxiliary Fuel Vapor Canister is added to a primary
closed bottom canister to increase capacity when a dual
(aux.) fuel tank is used. On the bottom is a hose which
connects to the primary canisters purge air inlet. On top
is a purge air inlet. Vapor overflowing from the primary
canister is stored in the auxiliary canister. During purge,
vapor flows through the auxiliary canister, the primary
canister and into the intake manifold for burning during
combustion.
A U X IL IA R Y
CANISTER
f~4~l AIR FLOW

DURING PURGE
| 2 j CARBON
f 5 j DUST CAP
I S I VAPOR FROM
PRIMARY CANISTER
FILTERS
4S-1018
Figure 7Auxiliary Vapor Canister
6E8--18 DRIVEABILITY AND EMISSIONS CARBURETED

Evidence of fuel loss or fuel vapor odor can be
caused by:
Liquid fuel leaking from fuel lines, fuel pump
or carburetor.
Cracked or damaged canister.
Inoperative bowl vapor vent valve.
Inoperative purge control valve.
Disconnected, misrouted, kinked, deteriorated
or damaged vapor hoses, or control hoses.
Bowl vent hose misrouted.
Air cleaner or air cleaner gasket inproperly
seated.
FUEL VAPOR CANISTER

V is u a lly ch e ck c a n is te r and rep la ce if cracke d,
damaged or saturated with fuel. Apply a short length of
hose to the carburetor bowl vapor tube of the canister
(lower tube), and blow into it, to determine that air will
pass the vapor vent valve into the canister. If not possible
to blow into the canister, it must be replaced.
VAPOR VENT CONTROL VALVE

Functional Test
Apply a short length of hose to the carburetor bowl
vapor tube of the canister (lower tube), and blow into it to
determine that air will pass the vapor vent valve into the
canister. If not possible to blow into the canister, it must be
replaced.
With a hand vacuum pump, apply vacuum 51 kPa (15"
Hg) to the vacuum sign al tube on the d iaphragm
assembly cover. The diaphragm should hold vacuum for
at least 20 seconds. If it does not, diaphragm is leaking,
and the canister must be replaced.
With vacuum still applied to the vacuum signal tube,
again attempt to blow into the carburetor bowl vapor tube
of the canister. Now air should not pass the vapor vent
valve into the canister, indicating that the valve is sealing
properly. If air does enter the canister past the vapor vent
valve, the valve is not functioning properly, and the
canister must be replaced.
PURGE CONTROL VALVE

Functional Test
Apply a short length of hose to the PCV tube of purge
valve assembly (lower tube), and attempt to blow through
it. Little or no air should pass into the canister. (A small
amount of air will pass if the canister has a constant
purge hole.)
With a hand vacuum pump, apply vacuum 51 kPa (15"
Hg) through the control vacuum signal tube to the purge
valve diaphragm. If the diaphragm does not hold vacuum
for at least 2 0 seconds, the diaphragm is leaking, and the
canister must be replaced.
If the diaphgram holds vacuum, again try to blow
through the hose connected to the PCV tube while
vacuum is still being applied. An increased flow of air
should be observed. If not, the canister must be replaced.
THERMOSTATIC VACUUM SWITCH (TVS)

REPLACEMENT
Thermal vacuum switches opens, closes, or switches
vacuum source w hen the ca lib ra tion tem perature is
reached. The following general checking procedures can
be used for all therm al vacuum switches. Refer to number

stam ped on base of valve or sw itch for calibration
temperature.
1. Allow TVS to cool below calibration temperature.
2. Inspect switch to make sure it is in good condition.

3. Connect hand vacuum pump(s) to output port(s) of
the TVS. (See vacuum hose schematic on Vehicle
Control Emission Information label.)
4. Apply 51 kPa (15" Hg) vacuum.
5. Heat TVS to a temperature above the calibration
temperature. Never apply a torch or open flame
directly to the TVS.
6 . C om pare vacuum
gage reading to the correct

reading indicated on switch or valve base.
NOTICE: Leakage of up to 7 kPa (2" Hg)

vacuum in 2 minutes is allowable and does not
mean a defective part.
7. If operation is satisfactory, reinstall valve or switch. If
valve or switch is defective, replace with a new part.
ON-VEHICLE SERVICE EECS

SYSTEM HOSES
Refer to Vehicle Emission Control Information label for
routing of system hoses.
When replacing hoses, use hose identified with the
word Fluoroelastromer.
VAPOR PIPE
The vapor pipe is secured to the underbody with clamp
and screw assemblies. Flexible hoses are connected at
the fuel tank and the fuel vapor canister. The pipe should
be inspected occasionally for leaks, kinks or dents and
repaired as required.
Repair
Repair vapor pipe in sections using brazed seamless
steel tu bin g m eeting GM S p ecifica tion 123M or its
e q u iv a le n t o r h o s e id e n tifie d w ith th e w o rd
Fluoroelastomer. Hose not so marked could cause early
failure or failure to meet emission standard.
Do not use copper or alum inum tubing to replace
s te e l tu b in g . T h o s e m a te r ia ls do n o t have
satisfactory durability to withstand normal vehicle
vibrations.
Do not use rubber hose within 4 inches (100 mm) of
any part of the exhaust system or within 10 inches
(254 mm) of the catalytic converter. Hose inside
diameter must match steel tubing outside diameter.
1. In repairable areas, cut a piece of fuel hose 4 inches
(100 mm) longer than portion of the line removed. If
more than a 6 -inch (152 mm) length of pipe is
removed, use a com bination of steel tubing and
hose so that hose lengths will not be more than 10
inches (254 mm). Follow the same routing as the
original pipe.
2 . Cut ends of pipe rem aining on vehicle square with a
tube cutter. Using the first step of a double flaring

tool, form a bead on the end of both pipe sections. If
pipe is too corroded to withstand bead operation

without damage, the pipe should be replaced. If a
new section of pipe is used, form a bead on both
ends of it also.
3. Use screw type hose clamp, Part Number 2494772,
or equivalent. Slide clam ps onto pipe and push
hose 2 inches (51 mm) onto each portion of fuel
pipe. Tighten clamps on each side of repair.
4. Pipes must be properly secured to the frame to
prevent chafing.
FUEL CAP
If a fuel tank filler cap requires replacement, use only a
cap with the same features. Failure to use the correct cap
can result in a malfunction of the system.
CANISTER REPLACEMENT
1. Disconnect hoses from canister. Mark hoses for
installation on new canister. Also refer to the Vehicle
2. Remove screw from bracket and remove canister.
3. Install canister and bracket screw.
4. Connect hoses to canister.
AUXILIARY VAPOR CANISTER

Replacement
1. Disconnect hose from canister.
2. Remove screw from bracket and remove canister.
3. Install canister and connect hose.
THERMOSTATIC VACUUM SWITCH

1.
2.
3.
4.
Drain coolant below level of switch.

Disconnect vacuum hoses.
Remove switch.
Apply a soft setting sealant to the threads of
therm ostatic vacuum switch. Sealant should not be
on the end of the switch.
5. Install switch, tighten to 14 N m (120 in. lbs.) and
then turn clockwise as required to align with hoses.
6 . Connect hoses.
7. Add coolant as required.
PARTS INFORMATION
PART NAME..........................................................GROUP
Canister, Fuel V a p o r.......................................................3,130
Solenoid, Fuel Vapor C a n is te r..................................... 3,140
AIR INJECTION REACTION (AIR) SYSTEM

GENERAL DESCRIPTION
The heavy duty emission engines with vehicle weight
over 8500 GVW have an AIR System with increased air
flow. The system is used to reduce carbon monoxide
(CO), and hydrocarbon (HC) emissions. The air injection
reaction (AIR) system provides a dditional oxygen to
continue the combustion process after the exhaust gases
leave the combustion chamber. The system diverts air
from the exhaust manifold at increased engine speed or
when an electrical malfunction is detected in the system.
The system used on a 4.8 L engine consists of an air
pump, air filter, air control valve, check valve, silencer, air
tem perature sw itch, control m odule, and necessary
plumbing.
AIR CONTROL VALVE (HFEAC) (Figure 8)

This valve is a high flow electric air control (HFEAC)
valve that has an electric solenoid to combine electronic
control with normal diverter valve function.
With ignition O N , the solenoid is energized through
the control m odule and the air control valve operates like
a s ta n d a rd iz e d d iv e rte r va lve . W ith th e s o le n o id
energized, air is directed to the exhaust manifold. During
an engine decel, when there is a rise in the manifold
vacuum signal, air is directed to the air cleaner or silencer
even though the solenoid is energized. The solenoid is
de-energized when there is high engine speed over a
prolonged period or a m alfunction of the electrical circuit.
SERVICE ENGINE SOON LIGHT
The air pump(s) is belt driven on the front of the

engine and supplies the air to the system.
If there is a malfunction in the control module, wiring

harness or solenoid(s), an amber SERVICE ENGINE
SOON light will illuminate on the instrument panel. The
SERVICE ENGINE SO O N light is O N w ith the
ignition key O N and the engine not running as a bulb
check (except 7.4 L). When the engine is started, the light
will remain on for three to six seconds and then turn off.
On a 7.4 L system, with ignition O N and the engine not
running, the SERVICE ENGINE SO ON light will come
O N and stay O N for 1 -2 seconds and then go O FF
as a bulb check.
Intake air passes through an external air filter to the

air pump(s).
DECELERATION CONTROL (Figure 9)
The system used on a 5.7 L or 7.4 L engine consists of

two AIR pumps, an air filter, two air control valves, two
check valves, a control module and necessary plumbing.
The 7.4 L engine also uses a control relay to operate the
SERVICE ENGINE SOON light.
AIR OPERATION
Air flow from the pump(s) passes through a control

valve(s) and an AIR pipe(s) and into the exhaust
manifold.
The check valve prevents back flow of exhaust into
the pump in the event of an exhaust backfire or
pump drive belt failure.
To help p re v e n t b a c k firin g d u rin g h ig h va cu u m

conditions a deceleration (gulp) valve is used with these
AIR systems. The high vacuum draws the deceleration
valve diaphragm down and opens the valve allowing air
from the air cleaner to flow into the intake manifold. This
air enters the air/fuel mixture to lean the rich condition
created by high vacuum when the throttle valve closes on
deceleration.

The vacuum draws the deceleration valve diaphragm
down and opens the valve allowing air from the air
cleaner to flow into the intake manifold.
DIAGNOSIS OF AIR
AIR SYSTEM
NOTICE: If the e n g in e o r u n d e r hood
compartment is to be cleaned with steam or
high-pressure detergent, the intake air filter
should be masked off to prevent liquids from
entering the pump.
[ 7 1 HIGH FLOW ELECTRIC

----- AIR CONTROL VALVE
|~6~| DECEL TIM ING

CHAMBER
n riD E C E L TIMING
ASSEMBLY
[T~] DIVERT AIR TO AIR

CLEANER OR SILENCER
r y ] VERY HIGH VACUUM

SIGNAL PORT
f T I ELECTRICAL
TERM INAL
f T I SOLENOID
09 25 84
AIR FROM PUMP
( T l AIR TO EXHAUST
PORTS
[To] PRESSURE RELIEF

ASSEMBLY
5S-1934
Figure 8Air Control Valve
The AIR System is not completely noiseless. Under

normal conditions, noise rises in pitch as engine speed
increases. To determ ine if excessive noise is the fault of
the Air Injection Reactor System, operate the engine with
the pump drive belt removed. If excessive noise does not
exist with the belt removed, check for the following:
A seized air pump.
Im proper m ounting and bolt torque of pump.
Im proper routing and connections of hoses.
CAUTION: Do not oil air pump.
Replace pump if none of the above conditions exist.
SERVICE ENGINE SOON LIGHT

If the SERVICE ENGINE SO O N light is on with the
engine running, refer to the proper C- 6 HD Chart for
diagnosis.
AIR PUMP
The air pum p is permanently lubricated and requires no
periodic maintenance.
Accelerate engine and observe air flow from hose(s). If
air flow increases as engine is accelerated, pump is
operating satisfactorily. If air flow does not increase or is
not present, proceed as follows:
L*
Inspect
1. For proper drive belt tension.

2. For a leaky pressure relief valve. Air may be heard
leaking with the pump running.
AIR CONTROL VALVE
f T ] AIR FLOW
[Tl EXHAUST GAS
f i~ 1 AIR CLEANER
\j2 EXHAUST VA LV E
[~9~] DECELERATION
VALVE
f~4~l INTAKE FLOW
f T o l M ANIFOLD
VACUUM
l~5~l INTAKE VA LV E
| 6 | COMBUSTION
CHAMBER
R l 1 DIAPHRAGM
A ir pum p should be w orking properly. D isconnect

solenoid connector at valve. W ith ignition O N , check for
12 volts at the connector. If there is no voltage, refer to the
proper C- 6 HD Chart for diagnosis. Start engine. Air
should go to the air cleaner or silencer. Connect the
solenoid connector and air should go to the exhaust ports.
Check for manifold vacuum signal at valve with engine
idling. Vacuum should be 10" Hg (34 kPa). During decel
and high vacuum signal, air should go to the air cleaner
and silencer. Replace valve if any of the conditions are not
correct.
f i l l VALVE
[ T l VACUUM BLEED
VALVE
Figure 9Deceleration Control
CHECK VALVE
4S -0507
Inspect
A check valve should be inspected whenever the
hose is d is c o n n e c te d from a c h e c k valve or
whenever check valve failure is suspected. (A pump

th a t had becom e ino pe rative and had show n
indications of having exhaust gases in the pump
would indicate check valve failure).
2. Blow through the check valve (toward the cylinder
head), then attempt to suck back through the check
valve. Flow should only be in one direction (toward
the exhaust manifold). Replace valve which does
not operate properly.
HOSE AND PIPES
I?
Inspect
1.
2.
3.
4.
Hose or pipe for deterioration or holes.

All hoses or pipe connections, and clam p tightness.
Hose or pipe routing. Interference may cause wear.
If a leak is suspected on the pressure side of the
system or if a hose or pipe has been disconnected
on the pressure side, the connections should be
checked for leaks with a soapy water solution. With
the pump running, bubbles will form if a leak exists.
CONTROL MODULE
Refer to the proper C-6 HD Chart for diagnosis of the
control module.
DECELERATION VALVE
1 . Remove air cleaner, plug air cleaner vacuum source
and connect tachometer.

With the engine running at specified idle speed,
remove the small deceleration valve signal hose
from the manifold vacuum source.
Reconnect the signal hose and listen for air flow
th ro u g h th e v e n tila tio n p ip e a nd in to th e
d e c e le ra tio n v a lve . T h e re s h o u ld a lso be a
noticeable speed drop when the signal hose is
reconnected.
If the air flow does not continue for at least one
se co n d o r th e e n g in e sp e e d d oe s not d ro p
noticeably, check the deceleration valve hoses for
restrictions or leaks.
If no restrictions or leaks are found, replace the
deceleration valve.
2.
3.
4.
5.
ON-VEHICLE SERVICE AIR

AIR WIRING DIAGRAM
Refer to the proper C-6 HD Chart for the wiring diagram.
DRIVE BELT
Inspect the drive belt for wear, cracks or deterioration
and replace if required. When installing new belt, it must
be s e a te d a n d fu lly s e c u re d in g ro o v e s o f A /C
compressor, AIR pump, generator, and crankshaft pulleys.
AIR INJECTION PUMP (Figures 10 through 13)
1 . Hold pump pulley from turning by compressing drive
belt, then loosen pump pulley bolts.

2. Loosen bolt, holding pump to m ounting brackets,
release tension on drive belts. Remove belt from
pulley.
3. Disconnect hoses at rear of pump.
4. Disconnect vacuum and electrical connections if

control valve is attached to the pump.
5. Remove pump pulley.
6 . Remove pump.
7. Remove control valve if attached.
++
Install or Connect
1. Install pump with control valve if attached.

2 . C onnect vacuum
and e le c tric a l co n n e c tio n s if

control valve is attached to pump.
3. Connect hoses at rear of pump.
4. Install pump pulley bolts and tighten equally to 15
N m (10 ft. lbs.). Tighten again within 10 minutes to
15 N m (10 ft. lb s .) u s in g a c lic k w re n c h ,
port-a-t'orque or other equivalent tool.
6 . Install pump drive belt and adjust tension.
AIR CONTROL VALVE (Figures 10 through 13)

1. Electrical connector from solenoid.
2. Air outlet hoses from valve.
3. Manifold vacuum hose.
4. Air control valve, gaskets and adapter.
|++| Install or Connect
1. Gaskets, adapter and air control valve.
2. Manifold vacuum hose.
3. Air outlet hoses to valve with clamps.
4. Electrical connector to solenoid.
CHECK VALVE (Figures 10 through 13)

1. Any parts required for access to valve.
2. Release clam p and disconnect air hoses from check
valve.
3. Valve from bracket.
4. Unscrew check valve from air injection pipe.
-<- Install or Connect

1 . Screw check valve onto air injection pipe.
2. Valve to bracket.
3. Position air hose on check valve and secure with
clamp.
4. Any parts removed for access.
AIR INJECTION PIPE ASSEMBLY

(Figures 10 through 13)
|< | Remove or Disconnect
1. Hose from check valve.

2. Check valve.
3. Nuts attaching pipes-to-manifold.
4. Pipe assembly.
-- Install or Connect
1. Nuts attaching pipes-to-manifold.
2. Check valve.
3. Hose to check valve with clamp.
r n A.I.R. PUMPTIGHTEN MOUNTING

----- SCREWS TO 25 N-m (18 FT. LBS.)
m CHECK V A L V E TIGHTEN NUT TO
----- 35 N-m (26 FT. LBS.)
HOSESILENCER TO A iR CONTROL V ALVE
HIGH FLOW ELECTRIC AIR CONTROL V A L V E TIGHTEN ATTACHING BOLTS TO 10 N-m (94 IN. LBS.)
in
SILENCER
i n AIR INJECTION PIPETIGHTEN NUTS

----- TO 28 N-m (20 FT. LBS.)
rn
FILTER
|~ 4l H O S E -A IR CONTROL VALVE TO CHECK V ALVE
DUCT (DRAIN HOLE MUST POINT DOWNWARD)
R o l HOSEFILTER TO PUMP
5S-1958
Figure 10AIR System 4.8 L Engine
m P U L L E Y TIGHTEN SCREWS TO 15 N-m (10 FT. LBS.).

TIGHTEN AGAIN WITHIN 10 MINUTES TO 15 N-m
(10 FT. LBS.).
m A.I.R. PUMP-TIGHTEN MOUNTING
'---- ' SCREWS TO 25N-m (18FT.LBS).
|~3~| ADAPTERTIGHTEN SCREWS TO 25 N-m
(18 FT. LBS.)
m AIR CONTROL VALVETIGHTEN SCREWS TO
---- 25 N-m (18 FT. LBS.)
[ 5 | HOSE-PUMP TO AIR CONTROL VALVE

f~6~|
---m
[~8~|
CHECK VALVETIGHTEN NUT TO 35 N-n

(26 FT. LBS.)
HOSE-AIR CONTROL VALVE TO CHECK VALVE
AIR INJECTION PIPETIGHTEN NUTS TO 28 N-m
(20 FT. LBS.)
[~9~] FILTER-DRAIN HOLE IN INLET HOSE MUST
POINT DOWNWARD
[Tol HOSE-FILTER TO PUMP
5S-1960
Figure 11AIR System 5.7 L (G)
r n
PULLEYTIGHTEN SCREWS TO 15 N m (10 FT. LBS.)

TIGHTEN AG AIN W ITHIN 10 MINUTES TO 15 N m
(10 FT. LBS.)
[ 6 j H O S E -A IR CONTROL V A LV E TO CHECK VALVE

[ T 1 CHECK V A L V E TIGHTEN NUT TO 35 N-m
(26 FT. LBS.).
p f ] A .I.R . PUMPTIGHTEN MOUNTING SCREWS TO

50 N m (36 FT. LBS.)
j 8 | A IR INJECTION PIPETIGHTEN NUTS TO 28 N-m

(20 FT. LBS.)
f T l AIR CONTROL V A L V E TIGHTEN SCREWS

TO 25 N m (18 FT. LBS.)
I 9 I F IL T E R -D R A IN HOLE ON INLET HOSE MUST

POINT DOWNWARD
fTl HOSE-PUMP TO AIR
CONTROL VALVE
fT o l HOSEFILTER TO PUMP
{ 5 | H O SE-AIR CONTROL VALVES TO A IR CLEANER
5S-1971
Figure 12AIR System 5.7 L (P)
rr~ ]
A.I.R. PUMPTIGHTEN MOUNTING SCREWS
1----- 1 TO 25 N-m (18 FT. LBS.)
CHECK V A L V E -T IG H T E N TO
35 N-m (26 FT. LBS.)
H O SE-VALVE TO CHECK VALVE
|~3~| AIR CONTROL V A L V E TIGHTEN MOUNTING

SCREWS TO 25 N-m (18 FT. LBS.)
| 5 I H O SE-VALVE TO AIR CLEANER

m
AIR INJECTION PIPE (TIGHTEN NUTS TO 28 N-m/

20 FT. LBS.) RIGHT SHOW N-LEFT SIMILAR
5S-1961
Figure 13 AIR S ystem 7.4 L Engine
HO SE-M ANIFOLD
DECELERATION
VALVE
[ T ] HOSE-M ANIFOLD
VACUUM
HO SE-AIR CLEANERTO-VALVE
f~4~] HOSEVALVE-TOINTAKE MANIFOLD
[T jD E C E L E R A T IO N VALVE
VACUUM
[T lH O S E - A IR CLEANER-TO| 2 | HOSEVALVE-TO -IN TAKE----- VALVE
MANIFOLD
5S-1965
Figure 14Deceleration Valve 4.8 L Engine
5S-1962
[T 1
CONTROL MODULE
[T ]
[T 1
ELECTRICAL
CONNECTOR
[ T ] DASH AND TOE PANEL

j j j ~ j CONTROL RELAY (7.4L)
BRACKET
_______________________________________5 S - 1969
Figure 18Control Module 5.7 L/7.4 L (P42)
I T ] DECELERATION
VALVE
H H HOSE-VALVE-TO
INTAKE MANIFOLD
p T I H O SE-M ANIFO LD
----- VACUUM
[ T ] HO SE-AIR CLEANERTO-VALVE
5S-1963
n ~ | CONTROL MODULE
l~2~l
ELECTRICAL CONNECTOR
[ T ] CONTROL MODULE
f~3 I BRACKET
[ T lN U T (TIGHTEN TO
20 N-m/15 FT. LBS.)
f 4 l PLENUM PANEL
5S-1967
Figure 17Control Module 5.7 L (G)
5S-1968
Figure 20Control Module 4.8 L Engine

: ILTER (Figures 10 through 13)
1. Filter from bracket.
2. Hose from air intake and pump.
|-n-| Install or Connect

1. Hose from air intake and pump.
2. Filter to bracket.
SILENCER - 4.8 L ENGINE (Figure 10)
++
1. Hose from the silencer.

2. S ile n ce r from the bracket.
Install or Connect
1. S ilen ce r to the bracket.
2. H ose to silencer.
DECELERATION VALVE (Figures 15 and 16)

1. Vacuum hoses from valve.
2. Screws securing valve to bracket.
3. Deceleration valve.
1. Deceleration valve.
2 . Screws securing valve to bracket.
3. Vacuum hoses to valve.
CONTROL MODULE
(Figures 17 through 20)
|<+| Remove or Disconnect
2 . Control module.
-4* Install or Connect

1 . Control module.
CONTROL RELAY (7.4 L ONLY)

Figures 18 and 19
4*+ Remove or Disconnect
1 . Electrical connector.
2. Control module.
Install or Connect
1 . Control module.
SERVICE ENGINE SOON LIGHT IS ON

The illumination of the SERVICE ENGINE SO ON light indicates that there is a m alfunction in the solenoid, control
module, or wiring. Check solenoid and m odule connectors for proper connection.
1. D isconnect air tem perature switch and install a
jum per wire across the terminals.
2. With ignition on, disconnect each solenoid connec
tor and with a test light, check for a light from the
pink/black wire to ground.
If light does not illuminate, check for an open
in circuit 39 to the solenoid.
If light illuminates, check for a light across ter
minals. Circuit is OK if there is a light. Check
solenoid coil resistance and if less than 20
ohms, replace solenoid and valve. If there is
no light, check for an open in circuit 900 to the
air temperature switch, an open in circuit 436
or faulty control module.
3. Connect solenoid connectors and disconnect both

connectors at control module. Check for a light be
tween term inals A and B of the 5 pin connector.
If the test light does not illuminate, check for
an open circuit to the module.
If the test light illuminates, check for a light
between 5 pin connector harness term inals
A and D.
If the test light illuminates, check for a short to
ground in circuit 419.
an open in circuit 900 between the solenoid
term inal B and the module 2 pin connector
term inal A . If circuit 900 is not open, replace
the control module.
Chart C-6HD-1 Air Management System 5.7 L Engine
SERVICE ENGINE SOON LIGHT IS ON

The illumination of the SERVICE ENGINE SOON light indicates that there is a malfunction in the solenoid, control
module, control relay, or wiring. Before diagnosis, check solenoid and module connectors for proper connection.
Chart C-6HD-2 Air Management System 7.4 L Engine

1 . This step is to determine if there is power to the air
temperature switch.
2. This step will insure that there is power to the circuit
by elim inating the air temperature switch. This step
will also check the wiring between the air tempera
ture switch and the solenoids.
3. This step will check the wiring between the sole
noids and ground, including the circuit inside the
control module.
4. This step will determ ine if the problem is a short to

ground in the SERVICE ENGINE SOON light cir
cuit or a m alfunction in the air management system.
5. This step checks for Bat. ( + ) at A and a ground at
B, to power up the control module.
6 . This step will determ ine if a ground signal is sent to
the relay because CKT919 is grounded outside the
module.
7. This step checks for a tach signal to the control
module.
CHART C-6HD-2
DISCONNECT AIR TEMPERATURE SWITCH

IGNITION "O N ." ENGINE STOPPED
WITH A TEST LIGHT, CHECK FOR A LIGHT FROM THE
PINK/BLACK WIRE TO GROUND.
LIGHT "OFF'
LIGHT "O N '
I
INSTALL A JUMPER WIRE ACROSS THE AIR
TEMP. SWITCH CONNECTOR TERMINALS.
DISCONNECT EACH SOLENOID CONNECTOR
AND WITH A TEST LIGHT, CHECK FOR A LIGHT
FROM THE YELLOW WIRE TO GROUND.
I
REPAIR OPEN
IN CKT 39 TO
THE SWITCH
LIGHT "O N " AT BOTH
SERVICE ENGINE SOON" LIGHT

"ON" AT ALL TIMES
7.4L ENGINE
CARBURETED
LIGHT "OFF" AT ONE OR BOTH
CHECK FOR A LIGHT ACROSS THE

TERMINALS (BOTH CONNECTORS)
REPAIR OPEN IN CKT 900 TO THE

SOLENOID
LIGHT "O N " AT BOTH CONNECTORS
LIGHT "OFF" AT ONE OR BOTH
X
X
USING AN O HM METER. CHECK THE

RESISTANCE OF EACH SOLENOID COIL
CHECK FOR OPEN IN CKT 436

IF OK. REPLACE CONTROL MODULE
20 OHMS OR GREATER
LESS THAN 20 OHMS
I
RECONNECT BOTH SOLENOID CONNECTORS
START ENGINE AND DISCONNECT CONTROL RELAY
NOTE "SERVICE ENGINE SOON" LIGHT
REPLACE THE VALVE ASSEMBLY
LIGHT "OFF'
LIGHT "O N '
ix
USING AN O HM METER, CHECK FOR CONTINUITY

BETWEEN TERMINALS "A " AND "D " OF THE HARNESS.
REPAIR SHORT TO
GROUND IN CKT 419
X
CONTINUITY
NO CONTINUITY
REPLACE CONTROL RELAY
DISCONNECT CONTROL MODULE CONNECTOR

USING A TEST LIGHT, CHECK FOR A LIGHT BETWEEN
TERMINALS "A " AND "B" OF THE HARNESS
1
LIGHT "OFF"
I
LIGHT" ON"
CHECK FOR OPEN IN CKT 900

OR CKT 150 TO THE MODULE
CHECK FOR A LIGHT BETWEEN TEMINALS

"A " AND "D " OF THE HARNESS.
X
LIGHT "OFF"
LIGHT "O N '
START ENGINE
USING A TEST LIGHT, CHECK FOR A FLICKERING LIGHT
BETWEEN HARNESS TERMINAL "C" AND GROUND
REPAIR SHORT TO
GROUND IN CKT 919
X
LIGHT DOES NOT"FLICKER"
LIGHT "FLICKERS"
zznzzn:
REPAIR OPEN IN CKT 121
REPLACE CONTROL MODULE
6S-2994
Chart C-6HD-2
SE R V IC E ENGINE SOON LIGHT IS ON

The illumination of the SERVICE ENGINE SO ON light indicates that there is a malfunction in the solenoid, control
module, or wiring. Check solenoid and m odule connectors for proper connection.
A
B
C
D
E
A
B
CONTROL
MODULE
6S-2919
C hart C6HD-3
1. Disconnect the air temperature switch and install a
jum per wire across the terminals.
2. With the ignition on, disconnect the solenoid con
nector and with a test light, check for a light from the
pink/black wire to ground.
If the light does not illuminate, check for an
open in circuit 39 to the solenoid.
If the light illuminates, check for a light across
the terminals. The circuit is OK if there is a
light. Check the solenoid coil resistance and if
less than 2 0 ohms, replace the solenoid and
valve. If there is no light, check for an open in
circuit 936 to the air temperature switch, an
open in circuit 436 or a faulty control module.
3. Connect the solenoid connector and disconnect

both connectors at the control module. Check for a
light between term inals A and B of the 5 pin
connector.
an open circuit to the module.
If the test light illuminates, check for a light
between the 5 pin connector harness term i
nals A and D.
If the test light illuminates, check for a
short to ground in circuit 419.
If the test light does not illuminate, check
for an open in circuit 936 between the
solenoid term inal B and the module 2
pin connector term inal A . If circuit 936
is not open, replace the control module.
6E-32 DRIVEABILITY AND EMISSIONS CARBURETED
EXHAUST G A S RECIRCULATION (EGR) SY ST E M
P H ASSEMBLY PLANT CODE

[~2~l PART NUMBER
H~j
EGR VALVE
[ 5 | DIAPHRAGM
[ 2 [ EXHAUST GAS
|~3~| INTAKE AIR
I 7 1 VALVE CLOSED
\ ]
VACUUM PORT
VALVE OPEN
s p r in g
4S-0536
4S 0538-6E
F igu re 21 EGR Valve
F igure 23 EGR V alve Id e n tific a tio n
GENERAL DESCRIPTION
source, the EGR pintle is closed and there is no exhaust

gas recirculation. When the throttle valves are opened,
vacuum is applied through the exposed vacuum signal
port(s) to the vacuum diaphragm in the EGR valve
through a connection tube. W hen the vacuum reaches a
pre-determ ined level, the diaphragm moves upward
against calibrated spring tension, pulling the pintle with it.
The pintle rises off the seat, allowing exhaust gas to flow
from the exhaust manifold to the intake manifold and into
the engine cylinders.
PURPOSE
The EGR system is used to lower NOx (oxides of
nitrogen) emission levels caused by high combustion
temperatures. It does this by decreasing com bustion
temperature.
The EGR system has a ported EGR valve (figure 21),
hose from a ported m anifold vacuum source and a
method to control the vacuum source.
A coolant tem perature TVS is used to control the
vacuum source.
OPERATION
The therm ostatic vacuum switch (TVS) blocks vacuum
to the EGR valve during cold engine operation (figure 22).
When the engine is warm, the TVS opens, which opens
the vacuum source to the EGR valve. At idle or wide-open
throttle, there is little or no vacuum from the vacuum
DATE BUILT
f~~4~~l LOOK HERE FOR LETTER

P = POSITIVE BACK PRESSURE
N = NEGATIVE BACK PRESSURE
BLANK = PORTED V ALVE
EGR VALVE
E E EXHAUST GAS
C H INTAKE FLOW
VACUUM PORT
m THROTTLE VALVE
c m VACUUM CHAMBER
H Q VALVE RETURN SPRING
h o i THERMAL VACUUM SWITCH
n n COOLANT
[ u ] DIAPHRAGM
4S -0002
Figure 22EGR System with TVS
Exhaust gas will be recirculated during periods of

normal intake manifold vacuum, when the throttle is open
beyond idle.
Figure 24TVS Location, 5.7 L-LT9

4. C o m p a re v a c u u m g a g e re a d in g (s ) w ith th e
procedures and in the TVS descriptions given under
each valve name.
5. Heat TVS to a temperature above the calibration
temperature. Never apply a torch or open flame
directly to the TVS.
6 . C om pare vacuum gage reading to the correct
reading indicated on switch or valve base.
NOTICE: Leakage of up to 7 kPa (2" Hg)

vacuum in 2 minutes is allowable and does not
mean a defective part.
f ~ n EGR VALVE
7. If operation is satisfactory, re-install valve or switch.

If valve or switch is defective, replace with a new
part.
f~2~l TVS (EGR)
ON-VEHICLE SERVICE EGR
4S-1050
Figure 25TVS Location, 7.4 L-LE8
DIAGNOSIS OF EGR
EGR SYSTEM
Too much EGR flow tends to weaken com bustion,
causing the engine to run roughly or stop. With too much
EGR flow at idle, cruise, or cold operation, any of the
following conditions may happen:
Engine stops after cold start.
Engine stops at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
If the EGR valve should stay open all of the time, the
engine may not idle.
Too little o r no EGR flo w a llo w s c o m b u s tio n
temperatures to get too high during acceleration and load
conditions. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
CLEANING MANIFOLD PASSAGE
I?
Inspect
If EGR p a s s a g e s in th e in le t m a n ifo ld in d ic a te
excessive build-up of deposits, the passages should be
cleaned. Care should be taken to insure that all loose
particles are completely removed to prevent them from
clogging the EGR valve or from being ingested into the
engine.
Do n ot w a s h
EG R v a lv e
in s o lv e n ts
or
degreaser permanent damage to valve diaphragm may
re s u lt. A ls o , s a n d b la s tin g o f th e v a lv e is n o t
recommended since this can affect the operation of the
valve.
SYSTEM HOSES
Refer to Vehicle Emission Control Information label for
routing of system hoses.
When replacing hoses, use hose identification with the
word Fluoroelastromer.
EGR VALVE
Refer to figure 23 to identify the EGR valve.
S ystem C heck
Diagnosis of the EGR system is covered in the chart at
EGR VALVE
Refer to EGR System Check at the end of this section
for diagnosis of the EGR valve.
The valve will open if vacuum is applied with the engine
not running.

A therm al vacuum switch opens, closes, or switches
vacuum source when the ca lib ra tion tem perature is
reached. The following general checking procedures can
be used for all thermal vacuum switches. Refer to number
stam ped on base of valve or sw itch for calibration
temperature.
1 . Allow TVS to cool below calibration temperature.
2. Inspect switch to make sure it is in good condition.
3. Connect vacuum gage(s) to output port(s) of the
TVS. (See vacuum hose schem atic on Vehicle
Control Emission Information label).
1.
2.
3.
4.
Air cleaner.
EGR valve vacuum hose at valve.
Bolts.
EGR valve from manifold.
Install or Connect
1.
2.
3.
4.
EGR valve to manifold (use new gasket).

Bolts.
Vacuum hose to EGR valve.
Air cleaner.

(Figures 24 and 25)
Replacement
1. Drain coolant below level of therm ostatic vacuum
switch (TVS).
2. Disconnect vacuum hoses.
3. Remove TVS.
4S-0611
Chart C-7C

4. Install replacement TVS with soft setting sealant
applied to male threads. Sealant should not be on
end of TVS.
5. Tighten TVS to 14 N m (120 in. lbs.), then turn
clockwise as required to align with hoses.
6 . Connect vacuum hoses.
7. Add coolant as required.
PARTS INFORMATION
PARTS NAME
GROUP
V a lv e ..................................................................................3,670
Gasket, EGR Valve ( 1 5 ) .................................................3,680
EARLY FUEL EVAPORATION SYSTEM (EFE)

ALL ENGINES EXCEPT 4.8 L
-tn
-m
---------------
03
Pn
VENT (FILTERED)
| 2 1 TO EFE VALVE
m
EE
|
MANIFOLD VACUUM
4S -0550
Figure 27Thermal Vacuum Switch

therm al vacuum switch (TVS) (figure 27). When vacuum is
applied to the actuator, the valve closes, causing the
intake manifold to heat up.
When coolant temperature increases, the TVS stops
vacuum to the actuator.
Results of Incorrect EFE Operation

No EFE when cold:
Engine may stum ble and stall during warm-up.
E n g in e ta k e s lo n g e r tim e to w a r m
up.
Choke may heat up and be off before engine is

warm.
GENERAL DESCRIPTION
EFE stays on:

Poor performance.
PURPOSE
The EFE system used on all engines provides a source
of rapid heat to the engine induction system during cold
driveaway. Rapid heating is desirable because it provides
quick fuel evaporation and more uniform fuel distribution
to aid cold driveability. It also reduces the length of time
carburetor choking is required, so it reduces exhaust
emissions.
Lack of power when warm due to superheated

gases.
Engine may overheat.
DIAGNOSIS OF EFE
GENERAL
OPERATION
The EFE system is a Vacuum Servo type that uses a
valve and vacuum actuator which increases the exhaust
gas flow under the intake manifold during cold engine
operation. The valve is located in the exhaust and the
vacuum actuator is vacuum operated (figure 26) by a
The operation of the EFE system is to be checked at

regular maintenance intervals. Refer to Section OB for
maintenance interval information.
VACUUM SERVO EFE DIAGNOSIS

TVS controlled. See Chart C-9C.
NUTTIGHTEN TO 20 N-m (15 FT. LBS.)
H I NUTTIGHTEN TO N-m (15 FT. LBS.)

[~2~| TENSION SPRING
J T 1 TENSION SPRING
] 3 | RIGHT HAND EXHAUST PIPE
[~3~| RIGHT HAND EXHAUST PIPE
f T ] SEAL
f T l SEAL
f l T l VALVE AND ACTUATOR
[ 5 | VALVE AND ACTUATOR

|~6~l EXHAUST MANIFOLD
1 0 | STUD-EXHAUST MANIFOLD
|T 1 M ANIFOLD VACUUM PIPE
P H MANIFOLD VACUUM PIPE
4S-1028
Figure 28Valve and Actuator 7.4 L
ON-VEHICLE SERVICE EFE

VALVE AND ACTUATOR (Figures 28 or 29)
1. Vacuum hose at EFE valve.
2. Exhaust pipe to manifold nuts, and tension springs.

3. Lower right hand exhaust (crossover) pipe and
seal com plete removal of pipe is not always
necessary.
4S-1029
Figure 29Valve and Actuator 5.7 L
4- Install or Connect
1. A p p ly a s o ft s e ttin g s e a la n t u n ifo rm ly on
replacement TVS male threads. No sealant should
be applied to sensor end of TVS.
2. TVS. Tighten to 14 N-m (120 in. lbs.) and then hand
to rq ue clockw ise as req uired to a lign TVS to
accommodate hoses.
3. Hoses to TVS ports.
4. Coolant as required.
4. EFE valve and actuator.

1. EFE valve (replace seals and gaskets if used).
2. Exhaust (crossover) pipe and seal.
3. Exhaust pipe to manifold nuts and tension springs.
Tighten nuts to 20 N m (15 ft. lbs.).
4. Vacuum hose at EFE valve.
COOLANT THERMAL VACUUM SWITCH (TVS)

(Figure 30)
The TVS is located on the engine coolant outlet
housing.
4- +
1. Drain coolant below level of engine coolant outlet

housing.
2 . Hoses at TVS ports.
3. TVS. Refer to num ber stamped on base of TVS for

calibration temperature.
l~H
E FE-TVS SWITCH
[~2~1 EG R-TVS SWITCH
Figure 30EFE Coolant TVS
4S-0549
VAAAAAAAy
VAAA/
ENGINE COOLANT
TEMPERATURE
4S-0614
Chart C-9C
1 . Engine coolant temperature should be below 4 0 C
(105F).
2. EFE valve should open above 40C (105F).
3. There should be at least 34 kPa (10" Hg) vacuum
available to EFE actuator diaphragm.
4. Valve may be seized up. It may be freed up by using

heat valve lubricant (part #1052627 or equivalent). If
valve does not free up, it must be replaced.
CHART C-9C
VACUUM ACTUATED EFE SYSTEM
CHECK
5.0L
CARBURETED
4S-0346
Chart C-9C
POSITIVE CRANKCASE VENTILATION (PCV)
Figure 31PCV Valve Cross Section
GENERAL DESCRIPTION
PURPOSE
A Positive Crankcase Ventilation (PCV) system is used
to provide more com plete scavenging of crankcase
vapors.
OPERATION
Fresh air from the air clea ne r is supplied to the
crankcase, mixed with blow-by gases and then passed
through a positive crankcase ventilation (PCV) valve into
the intake manifold (figure 32). The prim ary control is
through the PCV valve (figure 31) which meters the flow at
a rate depending on manifold vacuum.
To maintain idle quality, the PCV valve restricts the flow
w hen intake m anifold vacuum is h ig h. If abnorm al
operating conditions arise, the system is designed to
allow excessive amounts of blow-by gases to back flow
through the crankcase vent tube into the air cleaner to be
consumed by normal combustion.
Results of Incorrect PCV Operation

A plugged valve or hose may cause:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Oil in air cleaner.
Sludge in engine.
A leaking valve or hose would cause:
Rough idle.
Stalling.
DIAGNOSIS OF PCV
If an engine is idling rough, check for a clogged PCV
valve or plugged hose. Replace as required. Use the
following procedure:
1. Remove PCV valve from rocker arm cover.
2. Run the engine at idle.
3. Place your thum b over end of valve to check for
vacuum. If there is no vacuum at valve, check for
plugged hoses or m anifold port, or PCV valve.
Replace plugged or deteriorated hoses.
Figure 32PCV Flow

4. Turn off the engine and remove PCV valve. Shake
valve and listen for the rattle of check needle inside
the valve. If valve does not rattle, replace valve.
With this system, any blow-by in excess of the system
capacity (from a badly-worn engine, sustained heavy load,
etc.) is exhausted into the air cleaner and is drawn into the
engine.
Proper operation of the PCV System (figure 33) is
dependent upon a sealed engine. If oil sludging or
dilution is noted, and the PCV System is functioning
properly, check engine for possible cause and correct to
insure that system will function as intended.
ON-VEHICLE SERVICE PCV

See fig u re 33 fo r re p la c e m e n t o f PC V s y s te m
components.
An engine which is operated without any crankcase
ventilation can be damaged. Therefore, it is im portant to

replace the PCV valve and air clea ne r breather at
intervals shown in Section OB.
Periodically, inspect the hoses and clam ps and replace
any showing signs of deterioration.
PARTS INFORMATION
PART NAME
GROUP
Air C le a n e r.......................................................................3,402
Tube, C/Case V e n t ......................................................... 1,762
Hose, C/Case Vent V lv ...................................................1,762
[~ T [ PCV VALVE
[ 2 | AIR CLEANER
I 3 j CRANKCASE VENT
TUBE
|~4~1 PCV VALVE HOSE
| 5 | HOSE TO CANISTER
VIEW A
FIT] GROMMET
4S -0654
Figure 33Positive Crankcase Ventilation System
THERMOSTATIC AIR CLEANER (THERMAC)

GENERAL DESCRIPTION
PURPOSE
A heated intake air system is used to give good
driveability under varying clim atic conditions. By having a
uniform inle t te m p era ture , the fuel system can be
calibrated to reduce exhaust emissions and to eliminate
throttle blade icing.
OPERATION
The THERMAC air cleaner operates by heated air and
manifold vacuum (figure 34). Air can enter the air cleaner
from outside the engine com partm ent or from a heat stove
built around the exhaust manifold. A vacuum diaphragm
motor, built into the air cleaner snorkel, moves a damper
door, to adm it hot air from the exhaust manifold, outside
air, or a combination of both. Inside the air cleaner is a
temperature sensor that reacts to air intake temperature
and controls the amount of vacuum going to the motor.
Hot Air Delivery Mode. When the temperature is
below 8 6 F (30C), the sensor allows vacuum to the
motor and the dam per door will be up, shuting off
outside air and allowing only heated air from the
exhaust manifold to enter the air cleaner.
Regulating Mode. Between 8 6 F (30C) and 131 F
(55C) the dam per door allows both heated and
outside air to enter the air cleaner.
Outside Air Delivery Mode. W hen the temperature is

above 131 F (55C), the dam per door drops down
and only outside air enters the air cleaner.
THERMAC DELAY VALVE

Some applications use a delay valve on the hose
connecting the vacuum motor to the temperature sensor
(figure 35). When vacuum in this hose drops for any
reason, the check valve will bleed off the vacuum to the
vacuum motor slowly.
Results of Incorrect THERMAC Operation

Hesitation during warm-up can be caused by:
Heat stove tube disconnected.
Vacuum diaphragm motor inoperative (open to
snorkel).
No manifold vacuum.
Damper door does not move.
Missing air cleaner to carburetor seal.
Missing air cleaner cover seal or loose cover.
Loose air cleaner.
Lack of power, sluggish or spongy, on a hot engine
can be caused by:
Damper door does not open to outside air.
Temperature sensor doesnt bleed off vacuum.
Q D VACUUM DIAPHRAGM MOTOR

a
DIAPHRAGM SPRING
TEMPERATURE SENSOR
AIR BLEED VA LV E -C LO S E D
4B
AIR BLEED V A L V E P A R TIA LLY OPEN
[~4C~] AIR BLEED V A LV E -O P E N

l~5~| VACUUM HOSES
[~6 ~| DIAPHRAGM
| T 1 HEAT STOVE
pB~] HOT AIR (EXHAUST M AN IFO LD)
f 9 l DAMPER DOOR
f i o ] OUTSIDE INLET AIR
Pm
n n -
SNORKEL
A - HOT AIR DELIVERY MODE

B - REGULATING MODE
C - OUTSIDE AIR DELIVERY MODE
J?K <t
4S -0073
Figure 34THERMAC Operation
DIAGNOSIS OF THERMAC
THERMAC AIR CLEANER CHECK
1. Inspect system to be sure all hoses and heat stove
tube are connected. Check for kinked, plugged or
deteriorated hoses.
2. C h e c k fo r p re s e n c e and c o n d itio n
cleaner-to-carburetor gasket seal.
of
5. If the air cleaner fails to operate as described above,

perform vacuum motor check. If it operates, the door
may not be moving at the right temperature. If the
driveability problem is during warm-up, make the
temperature sensor check below.
a ir
3. With air cleaner assembly installed, damper door

should be open to outside air.
4. Start engine. Watch dam per door in air cleaner
snorkel. When engine is first started, damper door
should move and close off outside air. As air cleaner
warms up, dam per door should open slowly to
outside air.
[T l
SPOT WELDS
[~2~] MOTOR ASM.

m
RETAINING STRAP
FT]
INSTALL REPLACEMENT SENSOR ASM.

IN SAME POSITION AS O RIGINAL ASM.
4S -0649
Figure 36Replacing Vacuum

Diaphragm Motor
4S-0651
Figure 35THERMAC Delay Valve
Install or Connect
1 . New element.
2. Air cleaner cover, Do not over-torque nut (install
finger-tight).
VACUUM DIAPHRAGM MOTOR (Figure 36)

Figure 37Replacing THERMAC Sensor

Retaining Clip
VACUUM MOTOR CHECK
1. With engine off, disconnect vacuum hose at vacuum
diaphragm motor.
2. Apply at least 23 kPa (7 in. Hg) of vacuum to the
vacuum diaphragm motor. Dam per door should
completely block off outside air when vacuum is
applied. If not, check to see if linkage is hooked up
correctly.
3. With vacuum still applied, trap vacuum in vacuum
diaphragm motor by bending hose. Damper door
should rem ain closed. If not, replace vacuum
diaphragm motor assembly. (Failure of the vacuum
diaphragm motor assembly is more likely to be
caused from binding linkage or a corroded snorkel
than from a failed diaphragm . This should be
checked first before replacing the diaphragm.)
4. If vacuum motor checks OK, check vacuum hoses
and connections. If OK, replace the temperature
sensor.
TEMPERATURE SENSOR CHECK
1. Start test with air cleaner temperature below 3 0 C
(8 6 F). If engine has been run recently, remove air
cleaner cover and place thermometer as close as
possible to the sensor. Let air cleaner cool until
therm om eter reads below 30C (8 6 F) about 5 to 10
m inutes. R e in sta ll a ir clea ne r on e ngine and
continue to Step 2.
2. Start and idle engine. Damper door should move to
close off outside air immediately if engine is cool
enough. W hen dam per door starts to open the
snorkel passage (in a few minutes), remove air
cleaner cover and read thermometer. It must read
about 5 5 C (131 F).
3. If the dam per door is not open to outside air at
te m p e ra tu re in d ic a te d , te m p e ra tu re se n so r is
m alfunctioning and must be replaced.
ON-VEHICLE SERVICE
THERMAC
AIR CLEANER ELEMENT
1. Air cleaner.
2. Old element.
1. Air cleaner.
2. Vacuum hose from motor.
3. Drill out the two spot welds with a 1.6 mm (1/16-inch)
d rill, then enlarge as re q uired to rem ove the
retaining strap. Do not dam age the snorkel tube.
4. Motor retaining strap.
5. Lift up motor, cocking it to one side to unhook the
motor linkage at the control dam per assembly.
Install or Connect
1. Drill a 2.8 mm (7/64-inch) hole in snorkel tube at
center of vacuum motor retaining strap.
2. V a c u u m m o to r lin k a g e in to c o n tro l d a m p e r
assembly.
3. Use the motor retaining strap and sheet metal screw
provided in the motor service package to secure
motor to the snorkel tube. Make sure the screw does
not interfere with the operation of the dam per
assembly. Shorten screw if required.
4. Vacuum hose to motor and install air cleaner.
SENSOR (Figure 37)

1. Air cleaner.
2. Hoses at sensor.
3. Pry up tabs on sensor retaining clip. Remove clip
and sensor from air cleaner. Note position of sensor
for installation.
PARTS INFORMATION
PART NAME
GROUP
Air C le a n e r.......................................................................3,402
Element (Paper)................................................................ 3,410
Nut, A / C l........................................................................... 3,403
Seal, Air C leaner........... .............................................. 3,403
Sensor, A /C l....................................... ............................... 3,415
Motor, A/Cl Vac D ia p h ..................................................... 3,415
Tube, Eng Air Heat S to v e .............................................. 3,417
Stove, Eng Air H ea t......................................................... 3,417
THROTTLE RETURN CONTROL (TRC) SYSTEM

GENERAL DESCRIPTION
PURPOSE
The TRC system (figure 38), used on V 8 heavy duty
emission vehicles, consists of three m ajor components:
Throttle Lever Actuator Mounted as part of the
carburetor assembly, this device opens the prim ary
throttle plates a preset amount in excess of curb
idle, when engine vacuum is applied to it. This
a ctu a tin g vacuum is co n tro lle d by a separate
solenoid vacuum control valve.
S o le n o id V a cuu m C o n tro l V a lve M o u n te d
separately from the carburetor, this off-on valve is
held open, above a preset nominal engine speed, by
a signal from an engine speed sensor. The valve,
when open, allows a vacuum signal to be applied to
the throttle lever actuator as long as the preset
engine speed is exceeded.
Engine Speed Switch Mounted separately from
the solenoid vacuum control valve, this switching
device monitors engine speed at the distributor and
su p p lie s a co n tin u o u s e le ctrica l signal to the
solenoid vacuum control valve as long as the preset
engine speed is exceeded.
DIAGNOSIS OF TRC
Check hoses for cracking, abrasion, or deterioration
and replace as necessary. Check for shorted or broken
wires and be sure that electrical connectors are fully
engaged at the distributor, speed switch, and control
valve. Check system function for proper operation and
adjust as necessary.
1. Connect precision tachometer (capable of resolving
10 rpm) to the distributor TACH terminal.
2. Start engine and advance throttle to indicated 1890
rpm. Throttle lever actuator should be extended at
this speed.
3. Reduce throttle opening to indicated 1700 rpm.
Throttle lever actuator should be retracted at this
speed.
4. If the throttle lever actuator operates outside of the
1700 to 1890 rpm limits, the speed switch is out of
calibration and should be replaced.
5. If the actuator does not operate at any speed,
proceed with the following steps.
a. W ith a voltmeter, check for voltage at the
co n tro l valve and speed sw itch . T h is is
accom plished by connecting the negative
probe of the voltmeter to the engine ground
and in s e rtin g th e p o s itiv e p ro b e in th e
connector cavity of the voltage source wire. A
voltage of 12-14 volts should be measured at
this terminal on both the valve and speed
switch. When making this measurement, it is
not necessary to unplug the connector from its
com ponent. The vo ltm e te r probe can be
inserted in the connector body on the wire side
of the connector to contact the metal terminal.
b. If voltage is present at one device and not the

other, repair the engine wiring harness as
required.
c. If voltage is not present at either device, check
th e e n g in e h a rn e s s c o n n e c tio n s at th e
distributor and/or bulkhead connector. Repair
as required.
d. If the proper voltage exists at each device, to
check for proper solenoid valve operation,
ground the valve-to-switch connecting wire
terminal at the solenoid connector, using a
jum per wire. The throttle lever actuator should
extend (engine running).
e. If it does not extend, remove the hose from the
s o le n o id sid e p o rt th a t c o n n e c ts to the
actuator hose. Visually, check the orifice in
this port for plugging. Clear the orifice as
required. If not plugged, replace the solenoid
vacuum control valve.
f. If the actuator extends in Step D, ground the
valve-to-switch wire term inal at the speed
switch. If it does not extend, repair the wire
connecting the speed switch and valve. If it
does extend, check the speed switch ground
wire for ground it should read 0 volts
w hen checked w ith a voltm eter, w ith the
e n g in e
r u n n in g ,
check
th e
speed
s w itc h - to - d is tr ib u to r w ire
fo r p ro p e r
c o n n e c tio n . W ith b o th th e g ro u n d and
distributor wires properly connected, and if the
actuator does not extend when operating
above 1890 rpm, replace the speed switch.
THROTTLE LEVER ACTUATOR

CHECKING PROCEDURE
1. Disconnect valve to actuator hose at valve and
connect to an external vacuum source equipped

with a vacuum gage.
2. Apply 6 8 kPa (20" Hg) vacuum to the actuator and
seal off the vacuum source. If the vacuum gage
reading drops, then the actuator is leaking and must
be replaced.
3. To check the actuator for proper operation:
a. Check the throttle lever, shaft, and linkage to
be sure th a t they operate fre e ly w ith o u t
binding or sticking.
b. Start engine and run until warmed up and idle
is stable. Note idle rpm.
c. Apply 6 8 kPa (20" Hg) vacuum to the actuator.
Manually, open the throttle slightly and allow
to close against the extended actuator plunger.
Note the engine rpm.
d. Release and reapply 6 8 kPa (20" Hg) vacuum
to the actuator and note the rpm to which the
engine speed increased (do not assist the
actuator).
e. If the rpm obtained in Step D is not within 150
rpm of that obtained in Step C, then the
actuator plunger may be binding due to dirt,
c o rro s io n , v a rn is h , etc., or th e a c tu a to r
Figure 38Throttle Return Control System

diaphragm may be too weak. If binding is not
indicated, or cannot be corrected, then the
actuator must be replaced.
f. Release the vacuum from the actuator and the
engine speed should return to within 50 rpm of
the idle speed noted in Step 2. If it does not,
the p lu n g e r m ay be b in d in g due to d irt,
corrosion, varnish, etc. If the problem cannot
be corrected, the actuator must be replaced.
g. If the engine rpm noted in Step 3 is not within
the specified TRC speed range, the TRC
actuator must be adjusted. Refer to figure 39
and Vehicle Em ission C ontrol Inform ation
label fo r a d ju s tm e n t of the th ro ttle lever
actuator.
ENGINE AT OPERATING TEMPERATURE
CHOKE WIDE OPEN
CAM FOLLOWER STEPS OF FAST IDLE CAM
ADJUST IDLE SPEED SCREW TO OBTAIN SPECIFIED

CURB IDLE R.P.M. (SEE LABEL)
APPLY 68 kPa (20 ) WITH OUTSIDE VACUUM SOURCE
TO FULLY EXTEND PLUNGER
M ANU ALLY OPEN THROTTLE SLIGHTLY AND THEN
RELEASE AGAINST PLUNGER
WITH PLUNGER HELD INWARD, TURN PLUNGER IN OR
OUT TO OBTAIN SPECIFIED R.P.M. (SEE LABEL)
ON-VEHICLE SERVICE TRC

THROTTLE KICKER
Adjust
Refer to figure 38 and V ehicle Em ission C ontrol
Information label for adjustment of the throttle kicker.
|+ + | Remove or Disconnect(Figure 40)

1. Vacuum hose.
4S-1061
Figure 39Throttle Lever Actuator Adjustment
2. Bracket and throttle kicker.

3. Tab locking washer.
4. Throttle kicker.
DU
ATTACHING NUT
ca
TAB LOCKING WASHER
[ I]
THROTTLE KICKER
BRACKET
6S-2754
Figure 40Throttle Kicker

[+ + j Install or Connect
1. Throttle kicker.
p ri
THROTTLE LEVER ACTUATOR
2. Tab locking washer do not lock.
(~2~|
VACUUM HOSE
3. Bracket and throttle kicker.
fT I
NUT TIGHTEN TO 28 N-m (20 FT. LBS.)
F~4~l
SOLENOID VACUUM CONTROL V ALVE
4. Adjust throttle kicker.
____________________________________________4S-1063
5. Lock tab washer.

6 . Vacuum hose.
ENGINE SPEED SWITCH (Figure 41)

2. Engine speed switch,
Install or Connect
Figure 42Solenoid Vacuum Control Valve

SOLENOID VACUUM CONTROL VALVE
(Figure 42)
2. Vacuum hoses.
3. Solenoid vacuum control valve.
4- Install or Connect
1. Engine speed switch.
1. Solenoid vacuum control valve.

2. Vacuum hoses.
PARTS INFORMATION
PART NAME
GROUP
Throttle Kicker....................................................... Carb. Chart

Engine Speed S w itc h .....................................................3,440
Solenoid Vacuum Control Valve................................... 3,440
Figure 41Engine Speed Switch
6E9-1
SECTION 6E9
DRIVABILITY AND EMISSIONSD IESEL

CONTENTS
SUBJECT
PAGE
Description.................................................................................................................................................................. 6E9- 2
Crankcase Ventilation S ystem ................................................................................................................................. 6E9- 4
CDR Valve Check.................................................................................................................................................... 6E9- 4
CDR Valve Replacement........................................................................................................................................6E9- 5
Exhaust Gas Recirculation S y s te m ........................... ...........................................................................................6E9- 5
EGR System C h e c k ................................................................................................................................................6E9- 6
EGR Valve Replacement........................................................................................................................................6E9- 7
EPR Vacuum Actuator Replacem ent................................................................................................................... 6E9- 7
EPR/EGR Solenoid Replacem ent......................................................................................................................... 6E9- 7
Throttle Position Switch A djustm ent................................................................................................................... 6E9- 8
Vacuum Regulator Valve............................................................................................................................................6E9- 9
VRV Adjustm ent........................................... .......................................................................................................... 6E9- 9
Specifications......................................... .................................................................................................................... 6E9-10
Special T o o ls.............................................................................................................................................................. 6E9-10
All new General Motors vehicles are certified by the United States Environmental Protection Agency as con
forming to the requirements of the regulations for the control of air pollution from new motor vehicles. This
certification is contingent on certain adjustments being set to factory standards. In most cases, these adjustment
points either have been permanently sealed and/or made inaccessible to prevent indiscriminate or routine adjust
ment in the field. For this reason, the factory procedure for temporarily removing plugs, caps, etc., for purposes
of servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the
design.
For vehicles sold in Canada, also refer to the appropriate Canadian Service Manual Supplement.
6E9-2 DRIVABILITY AND EMISSIONSDIESEL
DESCRIPTION
c
A.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
" ) ,
F ro n t o f V e h ic le
EGR Valve
V a cuu m P um p
EPR S o le n o id
EPR Valve
EGR S o le n o id
In je c tio n P um p
F ast Id le S o le n o id
O il F ill Pipe
T h ro ttle P o s itio n S w itc h
C ra n kca se D e p re ssio n R e g u la to r Valve
B-09298
A.
1.
2.
3.
4.
5.
6.
7.
8.
9.
11.
12.
EGR Valve
V a cuu m P um p
EPR S o le n o id
EPR Valve
EGR S o le n o id
F ast Idle S o le n o id
O il F ill Pipe
T h ro ttle P o s itio n S w itc h
C ra n kca se D e p re s s io n R e g u la to r Valve
E n g in e Speed S e n s o r
B-09299
Figure 1R-V Emission System with

Light Duty Emissions
Figure 2G-Van Emission System with

Light Duty Emissions
The 6.2L diesel engine has controls to reduce exhaust

emissions while m aintaining good drivability and fuel
economy. The light duty emission engine (RPO LH 6 ) has
Crankcase Ventilation and Exhaust Gas Recirculation
(figures 1 and 2 ). The heavy duty emission engine (RPO

LL4) has Crankcase Ventilation and a Vacuum Regulator
Valve (figure 3).
DRIVABILITY AND EMISSIONSDIESEL 6E9-3
A.
B.
C.
6.
7.
8.
11.
13.
V acuum P um p (G-P S eries)
V acuum P um p (R-V Series)
F ast Idle S o le n o id
O il F ill Pipe
C ra nkca se D e p re ssio n R e g u la to r Valve
V acuum R e g u la to r Valve
B-09300
Figure 3Heavy Duty Emission System
CRANKCASE VENTILATION SYSTEM
A.
B.
21.
22.
23.
H ose to In ta ke
B lo w b y G a ses fro m th e C rankcase
C la m p s
B o lts
CDR Valve
A.
B.
C.
25.
26.
27.
28.
O u tle t Tube (G ases to In ta ke M a n ifo ld )

M o u n tin g B ra c k e t
In le t Port (G ases F ro m C rankcase)
C over
D iap hrag m
B o dy
S p rin g
B-09301
B-09302
Figure 4Crankcase Ventilation System
Figure 5CDR Valve Operation
The crankcase ventilation system is used on all 6.2L

diesel engines to reduce crankcase pressure at idle (fig
ure 4). This reduced pressure reduces engine oil leaks.
The system consists of connecting hoses and a Crank
case Depression Regulator (CDR) valve located at the
front right cylinder head.
The CDR valve is used to regulate the flow of crankcase
gases back into the engine. The valve limits vacuum in
the crankcase as the gases are drawn from the oil fill pipe
and into the intake manifold.
Intake manifold vacuum acts against a spring loaded
diaphragm to control the flow of crankcase gases (figure
5). Higher intake vacuum pulls the diaphragm closer to
the top of the outlet tube. This reduces the amount of
gases being drawn from the crankcase and also de
creases the vacuum in the crankcase. As the intake vac
uum decreases, the spring pushes the diaphragm away
from the top of the outlet tube. This allows more crank
case gases to flow to the intake manifold.
Refer to MAINTENANCE AND LUBRICATION (SEC.
OB) for diesel crankcase ventilation system maintenance
requirements.
The CDR valve is checked with a water manometer. The

U-tube m anometer indicates pressure or vacuum by the
difference in the height of the two colum ns of the fluid
(figure 6 ).
CDR VALVE CHECK

The purpose of the CDR valve is to maintain 0.75-1.0
kPa (3-4 inches of water) vacuum in the crankcase. Too
little vacuum may force oil leaks while too much vacuum
will pull oil into the air crossover.
Inspect
1 . C onnect one end of the m anom eter to the oil
dipstick hole.
The other end of the m anom eter is vented to
atmosphere.
2. Run the engine at idle.
3. The reading should be about 0.25 kPa ( 1-inch of
water) pressure at idle to 0.5-1.25 kPa (2-5 inches of
water) vacuum at full load.
Add the amount that the m anometer column
travels up to the am ount the other column
travels down to get the total pressure or
vacuum.
As an exam ple; 12.7 mm (one-half
inch) above zero plus 12.7 mm (one-half
inch) below zero gives a 25.4 (one-inch)
vacuum reading (figure 6 ).

CDR VALVE REPLACEMENT
B
1.
2.
3.
4.
Clamps (2 1 ) from the hoses.

Hoses.
Bolts (22).
CDR valve (23).

1.
2.
3.
4.
CDR valve to the bracket.

Bolts.
Hoses.
Clamps.
A.
B.
C.
D.
E.
F ro n t
E n g in e O il D ip s tic k Tube
V e n t To A tm o s p h e re
1/2 -ln c h A b ove Z ero
1/2-ln c h B e lo w Z ero
B-09541
Figure 6CDR Valve Test
EXHAUST GAS RECIRCULATION SYSTEM

*
The Exhaust Gas Recirculation (EGR) system is used

on 6.2 L diesel engines with Federal light duty emissions.
The EGR system (figure 7) consists of:
EGR valve.
Exhaust Pressure Regulator (EPR).
EGR solenoid.
EPR solenoid.
Throttle Position Switch (TPS).
Vacuum Pump.
Nitrogen oxides (NOx) are formed at high combustion
temperatures. The purpose of the EGR system is to re
duce these emissions.
Exhaust gases are introduced into the intake manifold
through the EGR valve (figure 8 ). These exhaust gases
act as an inert (non-combustible) ingredient in the com
bustion chamber. This reduces NOx through lower com
bustion temperatures.
At idle, the EPR solenoid is energized through the TPS,

allowing vacuum to close the EPR valve. This increases
exhaust backpressure. At a calibrated throttle angle, the
EPR soleniod is de-energized and the EPR valve is
opened.
At idle, the EGR solenoid is de-energized, allowing vac
uum to open the EGR valve. At a calibrated throttle angle,
the EGR solenoid is energized. This cuts off vacuum to
the EGR valve and the valve closes.
The EPR solenoid is normally de-energized and the
EGR solenoid is normally energized. The EPR solenoid is
de-energized before, or at the same tim e that the EGR
solenoid is energized.
There are three different cams used to change the tim e
when the EPR valve opens and the EGR valve closes.
The EPR valve is located between the exhaust manifold

and the exhaust pipe (figure 9). It increases exhaust back
pressure during idle to increase exhaust flow through the
EGR system. The EPR valve is normally open.
Blue Cam 0 degree difference.
The TPS is mounted on the throttle shaft of the injection

pump. As the throttle is opened, one switch contact opens
a circuit and another switch closes a circuit at calibrated
throttle angles.
Red Cam 10 degree difference.
Black Cam 5 degree difference.
Refer to figure 10 for a summ ary of EGR and EPR oper

ation.
A. EGR W ire (Yellow)

B. EPR W ire (Blue)
C. To 700 R4 T ra n s m is s io n
C o n v e rte r C lu tc h
D. In ta ke R u n n e r
E. E xh a u st G ases
F. 12 V o lts (P ink W ire)
1. EGR Valve
2 . V acuum P um p
3. EPR S o le n o id
4. EPR Valve
5. EGR S o le n o id
6 . In je c tio n P um p
9. T h ro ttle P o s itio n S w itc h
B-09543
F igure 7 EGR System
EGR SYSTEM CHECK

Heavy black exhaust smoke during acceleration usually
indicates a problem in the system.
1. S ta rt th e e n g in e a nd b rin g it to o p e ra tin g
temperature.
2 . Remove the air cleaner cover to observe EGR valve
operation.
3. With the engine at idle, the EGR valve should be
open (valve head in the up position and noticeable
e xhaust noise). If not, ch eck and co rre ct any
4.
5.
6.
7.
8.
9.
)
A.
B.
30.
31.
32.
In ta ke M a n ifo ld
F ro n t
S tud
EGR Valve
V acuum H o se (To A ir C leaner)
Figure 8EGR Valve
10.
B-09544
electrical and hose connection which may be loose

and/or disconnected.
Remove the vacuum hose from the EGR valve. The
valve head should drop with a noticeable reduction
in noise. Connect the hose.
The hose to the EGR valve should have 67.5 kPa
(20-inches of Hg) vacuum at idle. If vacuum is not
present, check the output of the vacuum pump at
the pump. The pump should produce a minimum of
67.5 kPa (20-inches of Hg) vacuum.
If vacuum is present at the EGR valve, but the valve
does not operate as the hose is put on and taken off,
the EGR valve is stuck and should be checked and
replaced if necessary.
Manually operate the throttle lever at the injection
pump through about 15 to 20 degrees of travel. The
EGR valve should close when the TPS reaches the
calibrated point.
Check the pink wire to the TPS for 12 volts (key on).
If 12 v o lts is n o t p re s e n t, c h e c k fo r lo o s e
connections, open wires, or a blown fuse.
With the key on, the blue wire from the TPS should
also have 12 volts. The blue wire feeds the EPR
solenoid. If the pink wire has 12 volts at idle, but the
blue wire does not, the TPS is inoperative and
should be changed.
With the engine off and the key on, operate the
throttle through 20 degrees of travel. At about 15
degrees, the TPS will stop sending 12 volts to the
blue wire (EPR). At about 20 degrees, the TPS will
supply 12 volts to the yellow wire (EGR). If not, the
TPS is inoperative.

11. Make sure the electrical connections are made at
the EGR/EPR solenoid assembly and that the hoses
are routed correctly.
12. If there is vacuum at the solenoid assembly and the
solenoids are receiving the proper electrical signal
but operation of the TPS does not operate the EGR
and/or EPR valve(s), the solenoid assem bly is
inoperative and should be replaced.
EGR VALVE REPLACEMENT
++

2. Vacuum hose from the EGR valve.
3. Studs.
4. EGR valve.
1. EGR valve.
2. Studs.
Seal the studs with Loctite 272 or equivalent.
3. Vacuum hose.
EPR VACUUM ACTUATOR

REPLACEMENT
1. The vacuum hose from the actuator.
2 . Clip from the valve lever.
/ 3. Bolt holding the actuator to the valve.

4. Actuator from the EPR valve.
A. N o rm a lly S p rin g Loaded O pen

4. EPR Valve
B-09545

1. Actuator to the EPR valve.
Figure 9EPR Valve
Throttle EGR
Position Valve
Idle to
15
Throttle
15 to
20
Throttle
EGR
Solenoid
EPR
Valve
EPR
Solenoid
Closed
Energized
(Vacuum
To Valve)
Open
Not Energized
(Vacuum
to Valve)
Open
Not Energized
(Vacuum to
Valve)
Open
Not Energized
(No Vacuum
to Valve)
Energized
(No Vacuum
to Valve)
Open
Not Energized
(No Vacuum
to Valve)
20 to
Closed
Full
Throttle
2. Bolt.
3. Clip.
4. The vacuum hose.
EPR/EGR SOLENOID
REPLACEMENT

1 . The vacuum hoses.
O b s e rv e th e
installation.
h o se
ro u tin g s fo r p ro p e r
3. Bolt (35).
4. Solenoid assembly.

F-00001
1. Solenoid assembly.
Figure 10EGR System Operation
2. Bolt (35).
4. The vacuum hoses.
c
A.
B.
C.
D.
E.
F.
G.
Front
C lo ckw ise R otation
Power Test Light O r O hm m eter
IGN (Pink Wire)
EGR (Yellow Wire)
O ptional Test Location
EPR (Blue o r V iolet W ire)
F-00008
Figure 12Testing the TPS for Continuity

8 . Return the throttle lever to the idle position and
remove the gage block.

9. Insert the proper switch open gage block and
rotate the throttle lever against the block. There
should be no continuity. If there is continuity, repeat
steps 1 through 9.
Refer to the Em ission Control Inform ation
label for correct gage block size.
10. Remove the gage block and ohmmeter.
THROTTLE POSITION
SWITCH ADJUSTMENT
1.
2.
3.
4.
5.
6.
7.
Tool Required:
J-33043, Gage Block.
D isco n n e ct th e th ro ttle p o sitio n sw itch (TPS)
connector.
Loosen the m ounting screws that hold the TPS.
Connect an ohmmeter or test light to the IGN (pink)
and EGR (yellow) term inals of the TPS (figure 12 ).
Insert the p ro pe r sw itch c lo s e d gage block
between the gage boss on the injection pump and
the wide open stop screw on the throttle shaft (figure
13).
Refer to the Em ission Control Inform ation
Rotate the throttle lever and hold the wide open stop
screw against the gage block.
Rotate the TPS until there is continuity between the
terminals.
Hold the TPS and tighten the mounting screws to 6
N m (53 in. lbs.).
11. Connect the TPS connector.
VACUUM REGULATOR VALVE
A. V acuum Gage
B. P ig ta il C o n n e c to r
C. C lo c k w is e R o ta tio n
D. To V a cuu m S o u rc e
E. W id e O pen S to p Pin
F. J -36142
B-07635
Figure 14Vacuum Regulator Valve Adjustment

A vacuum regulator valve is used on engines with
heavy duty emissions and automatic transmission. The
valve regulates the vacuum signal to the vacuum m odula
tor of a 400 automatic transm ission. The valve is mounted
to the injection pump and vacuum is supplied by the vac
uum pump.
8 . W ith the valve vacuum
9.
10.
VRV ADJUSTMENT
1.
2.
3.
4.
5.
Tool Required:
J-36142, Gage Block.
Loosen the vacuum regulator valve so it ts free to
rotate on the pump.
Attach a vacuum source of 67 5 kPa (20-inches
Hg. 1.5-inch Hg.) to the bottom vacuum port.
Attach a vacuum gage to the top vacuum port
(figure 14).
Insert the proper gage block between the gage boss
on the injection pump and the wide open stop screw
on the throttle lever (switch on position) (figure 13).
Refer to the Emission Control Inform ation
Rotate the throttle shaft and hold it against the gage
block.
NOTICE: Valve must be set while rotating the

valve body clockwise only.
6 . Slowly rotate the vacuum
regulator valve body

clockwise (facing the valve) until the vacuum gage
reads 38.8 2 kPa (11.5 0.6 inches Hg.) Hold the
valve body at this position and tighten the mounting
screws to 6 N m (54 in. lbs.).
7. Check by allowing the throttle shaft to return to the
idle stop position. Then rotate the throttle shaft back
against the gage block and read the vacuum gage.
The gage should read 38.8 2 kPa (11.5 0.6
inches Hg). If vacuum is outside of limits, reset the
valve.
11.
12 .
13.
set, confirm the detent

switch point by reading the resistance between the
ignition term inal (pink with black stripe) and the
detent term inal (orange).
Insert J-36142 between the wide open stop pin and
the wide open stop screw on the throttle lever.
Rotate the throttle lever against the tool. There
should be no continuity (infinite resistance).
Release the throttle lever and remove the switch
gage tool.
Rotate the throttle lever to wide open throttle (the
lever stop screw touching the pump stop pin).
Check the switch for continuity. The switch must
have continuity (1 to 0 ohms) before the throttle
reaches the wide open throttle position. If the switch
does not m eet th ese sp e c ific a tio n s , reset the
assembly by returning to step 1 and repeating the
entire procedure.
SPECIFICATIONS
TPS or VRV Screws........................................................................................................................................................ 6 N m(53 in. lbs.)
SPECIAL TOOLS
SECTION 6F
EXHAUST
CONTENTS
SUBJECT
PAGE
D escription..................................................................................................................................................................... 6F- 1
Diagnosis of Exhaust System...................................................................................................................................... 6F- 2
On-Vehicle S e rv ic e .......................................................................................................................................................6F- 2
Inspection................................................................................................................................................................... 6F- 2
Installing Exhaust Parts............................................................................................................................................ 6F- 2
Catalytic Converter Replacement............................................................................................................................6F- 4
Specifications.................................................................................................................................................................6 F -10
DESCRIPTION
Exhaust system designs will vary according to model
designation and intended use of the vehicle.
The exhaust pipe(s), muffler(s) and tailpipe(s) are stand
ard equipm ent. The exhaust system uses a ball joint cou
pling to secure the exhaust pipe to the engine manifold.
The ball joint will allow angular movement for alignm ent
purposes. The other connections use a slip joint coupling
design with a clamp and U-bolt.
The exhaust system is suspended by hangers attached
to the frame members. This will permit some movement of
the exhaust system, but should not permit the transfer of
noise and vibration into the vehicle.
Heat shields are used to protect both the vehicle and
the environment from the high temperatures developed
from the exhaust system, especially the catalytic con
verter.
The catalytic converter is an emission control device

added to the gasoline engine exhaust system to reduce
hydrocarbon and carbon monoxide pollutants from the ex
haust gas stream. The converter contains beads which
are coated with a catalytic material containing platinum
and palladium. The catalytic converter for the com puter
command control emission system will also contain rho
dium to reduce the level of nitrogen oxides. The catalyst
in the converter is not serviceable.
THE CATALYTIC CONVERTER REQUIRES THE USE

OF UNLEADED FUEL ONLY.
The diesel engine does not use a catalytic converter,
and uses only diesel fuel.
6F-2 EXHAUST
DIAGNOSIS OF EXHAUST SYSTEM

Exhaust system performance complaints, such as excessive back pressure, are noticeable by their effect on engine
performance. However, other m alfunctioning vehicle components have similar effects on engine performance and are
characterized by the same symptoms or complaints. Therefore, it is necessary to refer to the engine diagnosis procedure
when attempting to diagnose this type of problem.
NOTICE: Replacement of exhaust system parts MUST be OEM standard.
PROBLEM
POSSIBLE CAUSE
Vibrating or Rattling
From Exhaust System
Loose and/or misaligned components.
Restricted Exhaust
System
CORRECTION
Align, then tighten connections. Check
fo r d a m a g e d h a n g e r or m o u n tin g
brackets and clamps.
1. Kinked exhaust tubing.
2. Restriction within the muffler.
3. End of tail pipe obstruction.

4.
Exhaust Leakage
and/or Noise
Plugged catalytic converter (may result

from serious engine malfunction).
1. Leakage at exhaust component joints

and couplings.
2. Improperly installed or misaligned.
3. Exhaust manifold cracked or broken.
4 . Leak between exhaust manifold and cyl
inder head.
5. Damaged or worn seals or packing.
Burned or rusted out exhaust pipe heat
tube extension.
7. Burned or rusted out exhaust pipe.
8 . Burned or blown out muffler.
9. Broken or loose clamps and/or brackets.
6.
1. If possible, repair the damaged condi

tion, otherwise replace the component.
2. If restriction is suspected, remove the
muffler and visually check it. Replace
muffler if condition is doubtful.
3. Remove the obstruction, or if end is
crimped, straighten outlet.
4 . Replace the catalytic converter.
1. Tighten clamps or couplings to speci
fied torque.
2. Align, then tighten connections.
3. Replace the manifold.
4 . Tighten the manifold to cylinder head
nuts and bolts to specifications.
5. Replace the seals or packing as neces
sary.
6 . Replace the heat tube extensions as re
quired.
7. Replace the exhaust pipe.
8 . Replace the m uffler assembly.
9. Repair or replace as necessary.
ON-VEHICLE SERVICE
INSPECTION
INSTALLING EXHAUST PARTS
In s p e c t e x h a u s t p ip e s , c a ta ly tic c o n v e rte rs (if

equipped), mufflers and tailpipes for cracked joints, bro
ken welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, brackets and
insulators for cracks and stripped or corroded bolt
threads.
When installing a new exhaust pipe or m uffler and

tailpipe, on any model, check for proper alignm ent.
Rattles and noise vibrations in the exhaust system are
usually caused by m isalignm ent of parts. When aligning
the system, leave all bolts or nuts loose until all parts are
properly aligned, then tighten, working from the front to
the rear.
The exhaust system, including heat shields, must be

free of leaks, binding, grounding and excessive vibration.
These conditions are usually caused by damaged or
loose flange bolts, heat shields, brackets or pipes. If any
of these conditions exist, check the exhaust system com
ponents and alignment. Align and replace as necessary.
Exhaust system hangers, hanger brackets, and clamps

which are dam aged should be replaced to m aintain
exhaust system alignment.
Im portant
When jacking or lifting the vehicle from the frame
side rails, be certain lift pads do not contact the
EXHAUST 6F-3
C.
E.
12.
13.
14.
15.
15 N-m (11
36 N-m (27 Ft. Lbs.)
C lam p
C ro ss M e m b e r
S id e M em b e r
E xh a u st Pipe E x te n sio n
B-07309
F igure 1 Exhaust Pipe E xten sio n H anger P-M odel
VIEW B
C.
J.
21.
25.
26.
15 N-m (11 Ft. Lbs.)

11 N-m (8 Ft. Lbs.
Tail Pipe
H an g e r
B ra cket
VIEW A
Figure 2Tail Pipe Hanger (Typical) G-Model
B-07316
6F-4 EXHAUST
RV-MODEL
P-MODEL
G-MODEL
J. 11 N m (8 Ft. Lbs.)
L. 8 N m (6 Ft. Lbs.)
M. 4 N m (3 Ft. Lbs.)
F-02277
Figure 3Exhaust Heat Shields (Typical)

catalytic converter as damage to the converter will
result.
R e fe r to fig u r e s 1 th ro u g h 16 fo r c o m p o n e n t
replacement of the engine exhaust system.
Sealer 9985020 or equivalent is to be applied to all

slip joint connections.
CATALYTIC CONVERTER
REPLACEMENT
When replacing a muffler, the tailpipe should also

be replaced.
When installing the exhaust pipe to the engine
manifold, always use new packings and nuts. Clean
the engine manifold stud threads with a wire brush
before installing the new nuts.
1.
2.
3.

Heat shield.
Clamps at the front and rear of the converter.
Converter pipe-to-front-exhaust pipe and converter
pipe-to-rear-exhaust pipe.

Apply sealer 9985020 or equivalent at the slip joint
connection.
1. New catalytic converter into the exhaust pipe.
2. New U-bolts and clam ps at the front and rear of the
converter.
Check for clearance and alignm ent.
Tighten
Clamps and support to 40 N m (30 ft. lbs.).

3. Heat shield.
Figure 4Tail Pipe Hanger (Typical) RV-Model
EXHAUST 6F-5
A. 20 N m
B. 34 N-m (25 Ft. l d s .)
1. M a n ifo ld
2 . Seal A s s e m b ly
3. F lan ge
4. E x h a u s t P ipe
5. EFE Valve
B-07304
Figure 6Exhaust Pipe to Manifold (Typical)

RV-Model
Figure 7Catalytic Converter Clamping (Typical)

RV Model
C.
19.
23.
24.
15 N-m (11 Ft. Lbs.)

C a ta ly tic C o n ve rte r
B ra cket
C ro ss S ill
F-02279
Figure 5Front and Rear Muffler Hangers

(Typical) G-Model
6F-6 EXHAUST
Figure 8 E xhaust Pipe H angers (T ypical)

R V-M odel
Figure 9Catalytic Converter Support R-Model
EXHAUST 6F-7
(FRONT HANGERS)
B.
C.
13.
14.
19.
21.
22.
26.
34 N m (25 Ft. Lbs.)

15 N m (11 Ft. Lbs.)
C ro s s M e m b e r
S id e M e m b e r
C a ta ly tic C o n v e rte r
Tail Pipe
H anger
B ra cket
(REAR HANGER)
F-02278
Figure 11Tail Pipe Hanger (Typical) P-Model
6F-8 EXHAUST
P300(00) V8 (7.4 Liter)

P300(42) V8 (5.7 Liter) M20 & JF9
A. 20 N-m (15 Ft. Lbs.)

B. 34 N m (25 Ft. Lbs.)
C. 15 N-m (11 Ft. Lbs.) V 8 (5.7 Liter)
1. M a n ifo ld
2. Seal A s s e m b ly
3. Flan ge
4. E xh a u st Pipe
6. E x te n sio n
7. Seal
8 . Valve A n d A c tu a to r A s s e m b ly
P200 + 300(00) V8 (6.2 Liter)
Left Hand Manifold

V8 (7.4 And 5.7 Liter)
Figure 12Exhaust Pipe to Manifold P-Model
Figure 13Exhaust Pipe Hangers (Typical) P-Model
Typical
B-07306
EXHAUST 6F-9
C.
D.
12.
16.
21.
22.
15 N-m (11 Ft. Lbs

60 N m (44 Ft.
C lam p
M u ffle r
Tail Pipe
H anger
Figure 14Muffler Hangers (Typical) RV-Model
K100 + 200(03) V8
(7.4, 5.0 And 5.7 Liter)
Kv
K100(06) V8 (5.7 Liter)

E.
J.
K.
30.
36 N m (27 Ft. Lbs.)

11 N m (8 Ft. Lbs.)
18 N m (13 Ft. Lbs.)
H eat S h ie ld
F-02275
Figure 15Converter Heat Shield V-Model
F-02280
6F-10 EXHAUST
SPECIFICATIONS
Exhaust Pipe to M a n ifo ld .......................................................................................................................
Exhaust Pipe Hanger C la m p .................................................................... ............................................
Exhaust Pipe Hanger Bracket to Frame (RV-Model).........................................................................
Exhaust Pipe Extension Hanger to Bracket (P -M o de l)....................................................................
Exhaust Pipe C la m p ................................................................................................................................
Catalytic Converter C la m p .....................................................................................................................
Muffler Hanger C la m p ...........................................................................................................................
Muffler Hanger to F ra m e .......................................................................................................................
Tail Pipe Hanger C la m p .........................................................................................................................
Tail Pipe Hanger to Bracket/Side Member (P -M o de l).......................................................................
Catalytic Converter Support (R -M o d e l)...............................................................................................
Catalytic Converter Heat S h ie ld ............................................................................................................
Heat Shield A tta c h m e n t.........................................................................................................................
Heat Shield Attachment (RV200(00))...................................................................................................
Exhaust Heat Shields (R V -M odel)........................................................................................................
Exhaust Heat Shields (G -M o d e l)............................................................................. ............................
Exhaust Heat Shields (P-Model)............................................................................................................
N m
20
15
60
36
40
40
15
60
15
34
20
18
11
60
Ft. Lbs.
15
11
44
27
30
30
11
44
11
25
15
13
8
44
4
11
3
8
VACUUM PUMPS 6H-1
SECTION 6H
VACUUM PUMPS
CONTENTS
SUBJECT
PAGE
General Description........................................................................................................................................................ 6H-1

Belt Driven Vacuum P u m p ........................................................................................................................................6H-1
Gear Driven Vacuum Pump........................................................................................................................................6H-1
Diagnosis of Vacuum P um p..........................................................................................................................................6H-1
On-Vehicle S e rvice ........................................................................................................................................................ 6H-4
Belt Driven Pump Replacement............................................................................................................................... 6H-4
Gear Driven Pump Replacem ent............................................................................................................................. 6H-5
S p e cifica tio n s................................................................................................................................................................ 6H-6
Special T o o ls .................................................................................................................................................................. 6H-7
GENERAL DESCRIPTION
The vacuum pump is mounted on diesel engines and
supplies power for operating emission controls, transm is
sion modulators, cruise control, and air conditioning con
trols. It may be belt driven or gear driven. Refer to
Specifications at the end of this section for model
breakdown. The pump is a diaphram pump which does
not require periodic maintenance.
BELT DRIVEN VACUUM PUMP
GEAR DRIVEN VACUUM PUMP

The gear driven model is mounted at the top rear of the
engine. It is driven by a cam inside the drive assembly to
which it mounts. The drive housing assembly has a drive
gear on the lower end which meshes with the camshaft
gear in the engine. This drive gear causes the cam in the
drive housing to rotate. The drive gear also powers the
engine oil lubricating pump.
The belt driven model is bracket mounted at the right

front of the engine. It has a pulley attached which is
driven by the generator belt. With the exception of the
pulley, the vacuum pump is replaced as an assembly.
DIAGNOSIS OF VACUUM PUMP

Refer to figures 1 and 2 for diagnosis of the vacuum
pump.
6H-2 VACUUM PUMPS
AUTOMATIC TRANSMISSION (VACUUM MODULATED) WILL NOT SHIFT OUT OF FIRST

(LOW) GEAR. BLOCK WHEELS, APPLY PARKING BRAKE AND PLACE TRANSMISSION SE
LECTOR LEVER IN PARK OR NEUTRAL BEFORE STARTING ENGINE.
CONNECT VACUUM GAGE TO VACUUM PUMP INLET. AT
ENGINE IDLE, VACUUM SHOULD REACH -70 kPa (21
Hg) MINIMUM AT SEA LEVEL WITHIN 30 SECONDS (SEE
GRAPH FOR VACUUM AT OTHER ELEVATIONS).
LOW VACUUM OR
FLU C TU ATIN G GAGE
READING .
C H E C K S O K A Y L E A K IN
SYSTEM OTHER TH A N
VACUUM PUMP.
1. C H E C K G A G E A N D C O N
N E C T IO N S FOR LEAKS.
2. IF BELT D R IVEN, C H E C K BELT
TE N S IO N A N D PU LLEY FIT TO
SHAFT.
3. C H E C K IDLE RPM.
GO TO STEP 2
VACUUM PUMP DIAGNOSIS
R E C H E C K VACUUM G AG E
LOW VACUUM REPLAC E PUMP
VACUUM O K
I
GO TO STEP 2
GO TO STEP 1
VACUUM PUM P
MINIMUM ACCEPTABLE vs ALTITUDE
kPa
-17
-34
-51
-68
-84
B-05764
Figure 1Diagnosis of Vacuum Pump
VACUUM PUMPS 6H-3
VEHICLE VACUUM SYSTEM DIAGNOSIS
VACUUM PUMP
VACUUM GAGE
B-06869
Figure 2Diagnosis of Vacuum Pump
6H-4 VACUUM PUMPS
ON-VEHICLE SERVICE
1. V acuum P um p
2. P ulley
F-02046
Figure 3Belt Driven Vacuum Pump Assembly

Pulley to the pump with J-25033-B until the
pulley is flush with the end of the shaft.
BELT DRIVEN PUMP

REPLACEMENT
2. Generator belt.
3. Upper vacuum pump attaching bolts.
Raise the vehicle.
4. Engine coolant.
5. Lower radiator hose.
6 . Vacuum hose.
7. Lower vacuum pump attaching bolt.
8 . Vacuum pump including the pulley.
NOTICE: Do not tap pulley back onto pump

shaft. The pump could be damaged.

1. Vacuum pump assembly to the engine.
2. Vacuum pump lower attaching bolt.
Tighten
3. Vacuum hose.
Tool Required:
J-25034-B Pump Pulley Remover
Pulley from the pump with J-25034-B.
NOTICE: Do not pry from the back of the pulley.
Damage could occur to the pulley or pump.
Assemble (Figure 5)
Tool Required:
J-25033-B Pump Pulley Installer
4. Bottom radiator hose.

Lower the vehicle.
5. Upper vacuum pump attaching bolts.
6 . Generator belt and tighten it.
Refer to ENGINE COOLING (SEC. 6 B) for belt

specifications.
7. Battery cable.
8 . Engine coolant.
VACUUM PUMPS 6H-5

GEAR DRIVEN PUMP
REPLACEMENT
Tool Required:
J-29664 Manifold Cover Set
1. Air cleaner.
Im portant
Cover the air intake with J-29664 to prevent
foreign material from falling into the manifold.
2. Vacuum hose from the pump inlet.
3. Bolt and bracket holding the drive assembly to the
engine, block.
4. Pump and drive assembly.
NOTICE: Do not run the engine without the
vacuum pump installed. Since the oil pump is
powered by the vacuum pump drive gear, no oil
would circulate through the engine. The engine
could be damaged.
Inspect
Gasket on the pump assembly. Replace if
necessary.

1. New pump assembly making sure that the gear on the
drive assembly meshes with the gear on the engine
camshaft.
ft
Adjust (Figure 7)
Rotate the pump so the inlet tube faces the front

of the engine.
Pump should be on a 20-degree angle (figure 7).
2. Bolt and bracket.
Bolt to 27 N-m (20 ft. lbs.)

3. Vacuum hose to the inlet port.
4. Air cleaner.
Remove J-29664 from the air cleaner inlet.
Install the air cleaner.
6H-6 VACUUM PUMPS

5. In le t M a n ifo ld
6. C e n te rlin e o f E n g in e
7. R ear Face o f C ase
B-05876
Figure 7Vacuum Pump Positioned
SPECIFICATIONS
VACUUM PUMP APPLICATIONS
6.2 L V8
(379 Cu. In.)
Diesel Engine
Vacuum
Pump
Type
Pump
P/N
Federal
LH 6 , LL4
Gear Driven
7849302
California
LL4
Gear Driven
7849302
Federal
LH 6 , LL4
Belt Driven
7841746
California
LL4
Belt Driven
7841746
Federal
LL4
Belt Driven
7841746
California
LL4
Belt Driven
7841746
Model
Designation
RV Series
G Series
P Series
VACUUM PUMPS 6H-7
SPECIAL TOOLS
1. P um p P u lle y R em over
2. P um p P u lle y In s ta lle r
3. M a n ifo ld C over
F-02390
6H-8 VACUUM PUMPS__________
7A-1
SECTION 7
TRANSMISSION
CONTENTS
SUBJECT
PAGE
Automatic Transmission................................................................................................................................................ 7A-1

Manual Transm ission.................................................................................................................................................... 7B-1
C lu tc h ........................................................................................................................................................ ...................... 7C-1
Transfer Case.................................................................................................................................................................. 7D-1
SECTION 7A
CONTENTS
SUBJECT
PAGE
Description.................................................................................................................................................................... 7A- 2
Torque Converter...................................................................................................................................................... 7A- 2
Torque Converter Clutch (TC C )............................................................................................................................. 7A- 2
Transmission Identification......................................................................................................................................7A- 2
THM 400 (RPO M40).................................................................................................................................................. 7A- 4
THM 700-R4 (RPO M D 8 )..........................................................................................................................................7A- 4
Transmission D iagnosis.............................................................................................................................................. 7A- 6
Transmission Definitions..........................................................................................................................................7A- 6
Preliminary Checking P rocedure........................................................................................................................... 7A- 6
Transmission Fluid Info rm a tio n ............................................................................................................................. 7A- 6
Noise and Vibration.................................................................................................................................................. 7A- 7
Fluid Leaks................................................................................................................................................................ 7A- 7
Vacuum Modulator.................................................................................................................................................... 7A- 9
Diagnosis of Torque C o n verte r..................................................................................................................................7A-11
Diagnosis of Torque Converter Clutch (TCC)...........................................................................................................7A-12
THM 400 Preliminary C h e cking ..................................................................................................................................7A-14
Road T e s t.................................................................................................................................................................. 7A-15
Diagnosis of THM 400.................................................................................................................................................. 7A-16
Oil C irc u its ................................................................................................................................................................ 7A-25
THM 700-R4 Preliminary C h e ckin g ........................................................................................................................... 7A-31
Road T e s t.............................................................................................................................................................. .. .7A-33
Diagnosis of THM 700-R4............................................................................................................................................7A-35
Oil and Wiring C irc u its ............................................................................................................................................7A-43
On Vehicle S e rvice ...................................................................................................................................................... 7A-62
Parts Cleaning, Inspection and Replacement.......................................................................................................7A-62
Oil Cooler L in e s........................................................................................................................................................ 7A-63
Checking and Adding Fluid......................................................................................................................................7A-63
Shift L in k a g e ............................................................................................................................................................ 7A-63
TV Cable.................................................................................................................................................................... 7A-65
TV Cable Adjustment................................................................................................................................................7A-65
Changing the Fluid and F ilte r..................................................................................................................................7A-66
Detent Switch (THM 4 0 0 )........................................................................................................................................7A-67
Vacuum Modulator (THM 4 0 0 )............................................................................................................................... 7A-67
Speedometer Driven Gear/Vehicle Speed S e n s o r...............................................................................................7A-67
Governor.................................................................................................................................................................... 7A-68
2-4 Servo (THM 700-R 4)..........................................................................................................................................7A-71
Rear Extension Oil Seal............................................................................................................................................7A-73
Transmission Replacement..................................................................................................................................... 7A-74
S pe cifica tio ns..............................................................................................................................................................7A-76
Fastener Torque........................................................................................................................................................7A-76
Lubrication................................................................................................................................................................ 7A-76
Special T o ols................................................................................................................................................................ 7A-77
7A-2 AUTOMATIC TRANSMISSION
DESCRIPTION
100. C over
101. P ressure Plate
102. Turbine
103. S ta to r
104. Pum p
105. T h ru s t B e aring
106. S p rin g
107. T h ru s t S p a ce r
K
B-09166
Figure 1Torque Converter Components
TORQUE CONVERTER
The torque converter is of welded construction and is
serviced as an assembly. The unit is made up of two
vaned sections, or halves, that face each other in an oil
fille d h ou sin g. T he pum p h alf of the c o n ve rte r is
connected to the engine and the turbine half is connected
to the transmission.
When the engine makes the converter pump revolve, it
sends oil against the turbine, making it revolve also. The
oil then returns in a circular flow back to the converter
pump, continuing this flow as long as the engine is
running.
The converter also has a sm aller vaned section, called
a stator, that funnels oil back to the converter pump
through sm aller openings, at increased speed. The
s p e e d e d up o il d ire c ts a d d itio n a l fo rc e to th e
engine-driven converter pump, thereby m ultiplying engine
torque (figure 1 ).
TORQUE CONVERTER CLUTCH

(TCC)
The converter clutch assembly consists of a 3-element
torque converter with the addition of a converter clutch.
The converter clutch is splined to the turbine assembly,
and when operated applies against the converter cover
providing a m echanical direct drive coupling of the engine
to the transmission planetary gears. When the converter
c lu tc h is re le a s e d , th e a s s e m b ly o p e ra te s as a
conventional torque converter (figure 1 ).
The Torque C on verte r C lutch (TCC) system uses
controls that are internal as well as external to the
transmission.
The internal controls are:
TCC Solenoid Assembly Engergizes to redirect
transmission fluid to the converter clutch apply valve in
the auxiliary control valve assembly.
Third Gear Switch Closes when the transmission is

in third gear to complete electrical circuit of TCC
solenoid to the Electronic Control Module.
The external controls are:
Brake Release Switch To avoid stalling the engine
when braking, the converter clutch is released any
time the brakes are applied.
Electronic Control Module Receives input signals
and grounds TCC solenoid to apply the clutch when
proper operating conditions are met.
T h r o ttle P o s itio n S e n s o r S e n d s th ro ttle

in fo rm a tio n to th e E le c tro n ic C o n tro l M o d u le .
p o s itio n
Vacuum Sensor Sends engine vacuum (load)

information to the Electronic Control Module.
Vehicle Speed Sensor Sends vehicle speed
information to the Electronic Control Module.
Coolant Temperature Sensor Sends engine coolant
temperature information to the Electronic Control
Module.
TRANSMISSION IDENTIFICATION
All automatic transm issions have a metal identification
nameplate attached to the case exterior. The location of
this name plate is shown in figure 2. The information on
th e n a m e p la te w ill a s s is t in th e s e rv ic in g and
determination of replacement parts when ordered through
a GM Parts Catalog.
Additional transmission identification is provided on the
Service Parts Identification Label. This label contains
information on the regular production options (RPO) as
well as standard and mandatory options. This label is
affixed to the inside of each vehicle at the assembly plant.
Refer to Section 0A of this Service Manual for label
location and information.
AUTOMATIC TRANSMISSION 7A-3
M - INDICATES TRANSMISSION
TYPE IN OPTION LIST. (SPECIFIC
MODEL CODE IS FOUND ON THE
TRANSMISSION NAMEPLATE)
MX - DESIGNATES
SERVICE PARTS IDENTIFICATION

1 G 3 A
C90 C95
JA1 JA4
T87 UJ3
42T 409
R 4
DF3
K05
U23
7SB
DO NOT REMOVE
7 Y X E 5 1 0 0 0 0 1
D3C D33 D 8 E Z E|D FFL F40 GG1 GW9 G60 GU2 G89
K22 K99 L V 2( m W 9 IM X 0 ] n A 5 NB1 NK1 NK3 N33 N67 GJW
U35 VQ8 V10 WC3 WG2 YT 3 Y56 0 1 L 6SC 42B 421 42Q
8WT 9WT 11A 90A
PRINTED IN U.S.A.
PART NO. 14065987
SERVICE PARTS IDENTIFICATION LABEL
THM 400
THM 700-R4
F-02661
Figure 2Transmisison identification
120
110. O il P um p
111 . In te rm e d ia te R o lle r C lu tc h
112 . In te rm e d ia te C lu tc h
FORWARD
CLUTCH
RANGE
125
114. D ire ct C lu tc h
115 . Forw ard C lu tc h
118. O u tp u t S haft
DIRECT
CLUTCH
119. P la ne ta ry Gears
120. In p u t S h a ft
121. Torque C o n ve rte r
FRONT
BAND
INT.
CLUTCH
122.
123.
124.
125.
INT.
ROLLER
CLUTCH
F ro n t Band
Rear Band
Lo R o lle r C lu tc h
M ain S h a ft
LO
ROLLER
CLUTCH
REAR
BAND
PARK - NEUTRAL
FIRST
DRIVE
EFFECTIVE
SECOND
EFFECTIVE
THIRD
FIRST
EFFECTIVE
SECOND
EFFECTIVE
EFFECTIVE
SECOND
EFFECTIVE
Figure 3THM 400 Clutches and Operation
THM 400 (RPO M 40)
THM 700-R4 (RPO MD8)
The THM 400 is a fully automatic transmission for rear

wheel drive vehicles which provides three forward gear
ranges and a reverse (figure 3).
The THM 700-R4 is a fully automatic transmission for

rear wheel drive vehicles which provides four forward
gear ranges and a reverse (figure 4).
The major components of this transmission are:
The major components of this transm ission are:
Torque Converter.
Clutch Type Torque Converter.
Gear Type Oil Pump.
Vane Type Oil Pump.
Two Bands.
2-4 Band Assembly.
Three Multiple Disc Clutches.
Five Multiple Disc Clutches.
Two Planetary Gear Sets.
Two Planetary Gear Sets.
Two Roller Clutches.
One Sprag Clutch.
Valve Body Assembly.
One Roller Clutch.
External control connections to the transmission are:

Manual Linkage To select the desired operating
range.
Valve Body Assembly.

External control connections to the transm ission are:
Engine Vacuum To operate the vacuum modulator.
Manual Linkage To selected the desired operating

range.
12 Volt Electrical Signals To operate an electrical

detent solenoid.
Throttle Valve (TV) Cable To control shift points by

throttle opening.
110.
115.
117.
118.
119.
120.
121.
G E A R
R A N G E
2 -4
B A N D
R E V E R S E
IN P U T
C LU TC H
O V E R R U N
C LU TC H
1ST
D R 4
2N D
D R 4
O N
3R D
D R 4
4T H
D R 4
ON
1ST
LO
R EV.
F O R W A R D
C LU TC H
F O R W A R D
SPR A G CL.
A S S E M B LY
O N
O N
O N
O N
O N
O N
Lo R o lle r C lu tc h
2-4 Band
Reverse In p u t C lu tc h
O verrun C lu tc h
3-4 C lu tc h
F orw ard Sprag C lu tc h
3 -4
C LU TC H
ON
ON
3R D
D R 3
2N D
D R 2
124.
126.
127.
128.
129.
130.
O il Pum p
Forw ard C lu tc h
Lo A n d Reverse C lu tc h
O u tp u t S h a ft
P la ne ta ry Gears
In p u t S h aft
Torque C o n ve rte r
LO R O LL E R
C LU TC H
L O -R E V .
C LU TC H
O N
O N
O N
O N
O N
O N
O N
ON
O N
O N
O N
O N
O N
O N
O N
ON
O N
B-09169
Figure 4THM 700-R4 Clutches and Operation
TRANSMISSION DIAGNOSIS
TRANSMISSION DEFINITIONS
The following definitions are being provided to establish
a common language and assist the user in describing
transmission related conditions. Some of these terms or
conditions are used in the transmission sections of this
Service Manual.
Throttle Positions
Minimum Throttle the least amount of throttle
opening required for an upshift.
Light Throttle approximately 1/4 of accelerator pedal
travel.
Medium Throttle approximately 1/2 of accelerator
pedal travel.
Heavy Throttle approximately
of the accelerator
pedal travel.
Wide Open T hro ttle (WOT) full travel of the
accelerator pedal.
Full Throttle Detent Downshift a quick apply of the
accelerator pedal to its full travel, forcing a downshift.
Zero Throttle Coastdown a full release of the
accelerator pedal while the vehicle is in motion and in
drive range.
Engine Braking a condition where the engine is
used to slow the vehicle by manually downshifting
during a zero throttle coastdown.
Shift Conditions
Bump a sudden and forceful apply of a clutch or
band.
Chuggle a bucking or jerking condition that may be
engine related. May be most noticeable when the
converter clutch is engaged. Similar to the feel of
towing a trailer.
Delayed a condition where a shift is expected but
does not occur for a period of time. Samples of this
condition could be described as clutch or band
engagement does not occur as quickly as expected
during a part throttle or wide open throttle apply of the
accelerator or, when manually downshifting to a lower
range.
Also defined as LATE or, EXTENDED.
Double Bump ( Double Feel ) two sudden and
forceful applies of a clutch or band.
Early a condition where the shift occurs before the
vehicle has reached a proper speed and tends to labor
the engine after the upshift.
End Bump a firmer feel at the end of a shift as
compared to the feel at the start of the shift. Also
defined as END FEEL or, SLIP BUMP.
Firm a noticeable quick apply of a clutch or band
that is considered normal with a medium to heavy
throttle shift. Should not be confused with HARSH or
ROUGH.
Flare a quick increase in engine rpm accompanied
with a momentary loss of torque. This most generally
occurs during a shift. Also defined as SLIPPING.
Harsh ( Rough ) a more noticeable apply of a
clutch or band as compared to FIRM. This condition
is considered undesireable at any throttle position.
Hunting a repeating quick series of upshifts and

downshifts that causes a noticeable change in engine
rpm. An example could be described as a 4-3-4 shift
pattern. Also defined as BUSYNESS.
Initial Feel a distinct firmer feel at that start of a shift
as compared to the finish of the shift.
Late a shift that occurs when the engine is at a
higher than normal rpm for a given amount of throttle.
Shudder a repeating jerking sensation similar to
CHUGGLE but more severe and rapid in nature.
This condition may be most noticeable during certain
ranges of vehicle speed. May also be used to define
the condition after converter clutch engagement.
Slipping a noticeable increase in engine rpm
without a vehicle speed increase. A slip usually occurs
during or after initial clutch or band engagement.
Soft a slow, almost unnoticeable clutch apply with
very little shift feel.
Surge a repeating engine related feeling of
acceleration and deceleration that is less intense than
CHUGGLE.
Tie-Up a condition where two opposing clutches are
attempting to apply at the same time causing the
engine to labor wrth a noticeable loss of engine rpm.
Noise Conditions
Gear Noise a whine, most noticeable in first gear
and reverse that is related to vehicle speed. A gear
noise condition may become less noticeable or go
away after an upshift.
Pump Noise a high pitch whine that increases in
intensity with engine rpm. This condition may also be
noticeable in PARK and NEUTRAL operating ranges
with the vehicle stationary.
PRELIMINARY CHECKING
PROCEDURE
T his co n d itio n of an a uto m a tic tra n sm issio n not
operating properly may be influenced by one, or a
combination of the following items:
Fluid level high/low.
Engine performance.
T.V. cable adjustment.
Manual linkage adjustment.
Internal fluid leaks.
Electrical system.
Transmission or other mechanical component.
Vacuum modulator.
TRANSMISSION FLUID
INFORMATION
Checking fluid level, color and condition at regular
intervals will provide early diagnosis information about the
transm ission. This inform ation may then be used to
correct a condition that, if not corrected early, could result
in major transmission repairs.

When adding or changing cluid, use only DEXRON
II, or equivalent. Refer to Section OB of this Service
M anual for m ainten an ce in fo rm a tio n and s e rvicin g
intervals.
Fluid level should be checked when it reaches normal
operating temperatures of 88-93C (190-200F). This
temperature is reached after approximately 24 km (15
miles) of highway driving (figure 5).
Fluid color:
Should be dark red (may be dark green) (figure
5).
Inaccurate fluid level readings will result if checked
immediately after the vehicle has been operated:
In high ambient tempearatures above 32C
(90 F).
At sustained high speeds.
In heavy city traffic during hot weather.
As a towing vehicle.
In commercial service (taxi or police use).
Rotate torque converter 120 (1/3 turn).

Flexplate to torque converter attaching bolts.
Tighten

Converter shield bolts.

4. Start the engine and check for vibration. Repeat this
procedure until the best possible balance is obtained.
Some engine/transmission combinations cannot be

balanced in this manner due to limited clearances
between the torque converter bolts and engine. Be
sure bolts do not bottom out in lug nuts or the torque
converter coverter could be dented and cause internal
damage.
NOISE AND VIBRATION

A noise or vibration that is noticeable when the vehicle
is in motion, MAY NOT be the result of the transmission.
If noise or vibration is noticeable in Park (P) and
Neutral (N) with engine at idle, but is less noticeable as
RPM s increase, the cause may be from poor engine
performance.
1?
Inspect
Tires for
Uneven wear.
Imbalance.
Mixed sizes.
Mixed radial and bias ply.
Suspension components for
Alignment and wear.
Loose fasteners.
Engine/Transmission mounts for
Damage.
Loose bolts.
Transmission case mounting holes for:
Missing bolts, nuts, studs.
Stripped threads.
Cracks.
Flexplate for:
Missing or loose bolts.
Cracks.
Imbalance.
Torque converter for:
Missing or loose bolts or lugs.
Missing or loose balance weights.
Imbalance.
VIBRATION TEST PROCEDURE

2. With the engine at idle speed and the transmission in
Park (P) or Neutral (N), observe the vibration.
3. Shut off the engine.
I?
Inspect
Converter shield attaching bolts.
Flexplate to torque converter attaching bolts.
FLUID LEAKS
The cause of most external leaks can generally be
located and repaired with the transmission in the vehicle.
METHODS FOR LCOATING LEAKS

General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 15 miles or until normal
operating temperatures are reached.
4. Park the vehicle over clean paper or cardboard.
5. Shut off the engine and look for fluid spots on the
paper.
6 . Make the necessary repairs.
Powder Method
1. Thoroughly clean the suspected leak area with solvent.
2. Apply an aerosol type powder (foot powder) to the
suspected leak area.
3. Operate the vehicle for about 15 miles or until normal
operating temperatures are reached.
4. Shut off the engine.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source.
6 . Make necessary repairs.
Dye And Black Light Method

A fluid dye and black light kit is available from various
tool manufacturers.
1. Follow the manufacturers recommendations for the
amount of dye to be used.
2. Detect the leak with the black light.
3. Correct cause of leak.
REPAIRING THE LEAK

Once the leak has been pinpointed and traced back to
its source, the cause of the leak must be determined in
order for it to be repaired properly. If a gasket is replaced,
but the sealing flange is bent, the new gasket will not
repair the leak. The bent flange must be repaired also.
tfi&au
A. FLUID LEVEL INDICATOR

B. LEVEL TO BE IN CROSS-HATCHED AREA ON FLUID LEVEL INDICATOR BLADE.
CHECK AT OPEARTING TEMPERATURE.
F-02662
Figure 5Checking Fluid Level, Color and Condition

Before attempting to repair a leak, check to be sure that
the following conditions are correct as they may cause a
leak.
G askets
1. Fluid level/pressure is too high.
2. Plugged vent or drain-back holes.
3. Im pro pe rly torqued fa ste ne rs or d irty/d am a ge d
threads.
4. Warped flanges or sealing surface.
5. Scratches, burrs or other damage to the sealing
surface.
6 . Damaged or worn gasket.
7. Cracking or porosity of the component.
8 . Improper sealant used (where applicable).
Seals
1. Fluid level/pressure is too high.
2. Plugged vent or drain-back holes.
3. Damaged seal bore (scratched, burred or nicked).
4. Damage or worn seal.
5. Improper installation.
6 . Cracks in component.
7. Manual or output shaft surface scratched, nicked or
damaged.
8 . Loose or worn bearing causing excess seal wear.
POSSIBLE POINTS OF FLUID LEAKS (Figure 6 )
1. Transmission oi pan or side cover:
Attaching bolts not correctly torqued.
Improperly installed or damaged gasket.
Oil pan or mounting face not flat.
2 . Case leak:
Filler pipe multi-lip seal damaged or missing.
Filler pipe bracket mislocated.
T.V. cable multi-lip seal missing, damaged or
improperly installed.
Governor cover or gasket damaged or missing.
Speedometer driven gear/speed sensor seal
damaged.
Manual shaft seal damaged.
O il co o le r co n n e cto r fittin g s loose or da m ag ed.
3. Leak
4. Fluid
Parking pawl shaft cup plug loose (if equipped).

Line pressure pipe plug loose.
Porous casting.
at converter end:
Converter seal damaged.
Seal lip cut. (Check converter hub for
damage).
Bushing moved forward and damaged.
Garter spring missing from seal.
Converter leak in weld area. (Refer to Torque
Converter.)
Porous casting (case, pump).
comes out the vent pipe or fill tube:
Over-filled.
Water or coolant in cluid. Fluid will appear milky.
Case porous.
Incorrect fluid level indicator.
Plugged vent.
Drain back holes plugged.
M ispositioned oil pump to case gasket (if
equipped).
CASE POROSITY REPAIR

1. Clean the leak area with solvent and air dry.
CAUTION: Epoxy cement may cause skin

irritations and eye damage. Read and follow all
information on the container label as provided
by the manufacturer.
2. Mix a sufficient amount of epoxy cement, GM 1360016,
or e q u iv a le n t, fo llo w in g the m a n u fa c tu re rs
recommendations.
3. While the transmission case is hot, apply the epoxy
cement with a clean, dry soldering acid brush.
4. Allow the epoxy cement to cure for three hours before
starting the engine.
5. Repeat the fluid leak diagnosis procedures.
VACUUM MODULATOR
A vacuum m odulator can cause one or more of the
following complaints.
1. Harsh upshifts and downshifts.
2. Delayed upshifts.
3. Soft upshifts and downshifts.
4. Slips in low, drive and reverse.
5. Transmission overheating.
6 . Engine burning transmission oil.
If any one of the above complaints are encountered,
the modulator must be checked.
CAUSES OF IMPROPER VACUUM AT MODULATOR

1. Engine.
a. Tune up.
b. Loose vacuum fittings or improperly routed
hoses/lines.
c. Vacuum operated accessory leak (hoses,
vacuum valve, etc.).
d. Engine exhaust system restricted.
e. DieselVacuum Regulator Valve adjustment.
(Refer to DIESEL FUEL INJECTION, SEC. 6 C 6 ).
2. Vacuum line to the modulator.
a. Leak.
b. Loose fitting.
c. Restricted orifice or incorrect orifice size.
d. Carbon build up at modulator vacuum fitting.
e. Pinched line.
f. Grease in pipe (delayed or no upshift-cold).
VACUUM DIAPHRAGM CHECK

1. Raise the vehicle and disconnect the vacuum line at
the modulator.
2. Turn the modulator so the vacuum line stem points
downward.
3. If transmission oil comes out, the modulator must be
replaced.
4. If gasoline and/or water vapor are found in a vehicle
which may be exposed to -12C (10F) temperatures or
below, the modulator must be changed.
5. If oil is not found in the vacuum side of the modulator,
but the transmission oil level is continually low, and no
external leaks are found, there is a possibility that a pin
hole leak exists in the diaphragm and the modulator
should be replaced.

>
A. Oil Pan
B. Case
C. C ooler C onnecto rs &
Plugs
D. TV Cable Seal
E. Servo Cover
F.
G.
H.
I.
J.
K.
Oil F ill Tube Seal

Oil Pump Seal A ssem bly
Oil Pump To Case Seal
Converter
Vent
E lectrical C onnector Seal
L.
M.
N.
0.
P.
Manual Shaft Seal

G overnor Cover
Speedo Seal
E xtension To Case Seal
E xtension Oil Seal
A ssem bly
B-08659
Figure 6Possible Leak Points

LOAD CHECK
GAGE
INDICATOR
1. Install a modulator that is known to be good on either

end of tool J-24466.
2. Install the moduator in question on the opposite end of
the gage (figure 7).
3. Holding the modulators in a horizontal position, bring
them slowly together under pressure. If the modulator
in question is bad, the gage line will remain blue. If the
modulator is good, the gage line will be white. When
m aking the c o m p a ris o n , make sure th a t both
modulators are of the same type. The part numbers
are stamped on the dome of the modulator.
J-24466
SLEEVE ALIGNMENT CHECK

Figure 7Checking the Modulator
ATMOSPHERIC LEAK CHECK
1. Apply a thick coating of soap bubble solution to the
vacuum connector pipe seam and the crimped upper
to lower housing seam.
2. Using a short piece of rubber hose, apply air pressure
to the vacuum pipe by blowing into the tube.
3. If bubbles appear, replace the modulator.
Do not use any method other than human lung
power for applying air pressure, as pressures over
v
.i
.
,
41.37 kPa (6 psi) may damage the modulator.
1. Roll the main body of the modulator on a flat surface.

2. If the sleeve is not concentric to the can, replace the
modulator.
3. If the plunger is not free, replace the modulator.
The following items should also be checked as a
possible cause of the problem.
1. Check freeness of modulator valve in transmission
case.
2. Check the vacuum line from the manifold or vacuum
pump to modulator for holes, cracks or dents. Check
the rubber hose connection at the modulator and at the
intake manifold or vacuum pump for leaks.
DIAGNOSIS OF TORQUE CONVERTER

Converter Shudder
1 . Torque converter assembly.

2 . Valve body.
1. Internal damage.
2 . Converter clutch shift valve stuck.
3. Oil pump assembly.
3. a.
b.
4. a.
b.
c.
5. a.
b.
6 . a.
b.
4. Oil filter.
5. Miscellaneous.
6 . Input housing and shaft assembly.
No Converter Clutch
Release
CORRECTION
POSSIBLE CAUSE
PROBLEM
Converter clutch apply valve stuck.

Restricted oil passage.
Crack in filter body.
Flash restricting filter neck.
Seal cut or damaged.
Low oil pressure.
Engine not tuned properly.
Turbine shaft seal cut or damaged.
Turbine shaft retainer and ball as
sembly damaged.
1 . Solenoid
2 . Converter.
1. External ground.
2 . Internal damage.
3. Converter clutch apply valve stuck.
7A-12 AUTOMATIC TRANSMISSIONS
DIAGNOSIS OF TORQUE CONVERTER (CONT.)

PROBLEM
No C on verte r C lutch
A p ply
POSSIBLE CAUSE
1. Electrical.
2. Converter.
4. Valve body assembly.
5. Input housing and shaft.
CORRECTION
1. a. 12 volts not supplied to transm is
sion.
b. Outside electrical connector dam
aged.
c. Inside electrical connector, wiring
harness or solenoid damaged.
d. Electrical short (pinched solenoid
wire).
e. Solenoid not grounded.
f. In c o rre c t o r d a m a g e d p re s s u re
switches.
2. Internal damage.
3. a. Converter clutch apply valve stuck
or assembled backwards.
b. Converter clutch apply valve retain
ing ring mispositioned.
c. Pump to case gasket mispositioned.
d. Orifice cup plug plugged.
e. Solenoid seal cut or damaged.
f. Orifice cup plug omitted from cooler
in passage.
g. High or uneven bolt torque (pump
body to cover).
4. Valves stuck.
a. Converter clutch shift valve.
b. Throttle valve.
5. a. Turbine shaft seal cut or damaged,
b. Turbine shaft retainer and ball as
sembly plugged.
STATOR ASSEMBLY FREEWHEELS
STATOR ASSEMBLY REMAINS LOCKED UP
If the stator roller clutch becomes ineffective, the stator

assembly freewheels at all times in both directions. With
this condition, the vehicle tends to have poor acceleration
from a standstill. At speeds above 48 to 56 km/h (30-35
mph), the vehicle may act normal. If poor acceleration
problems are noted, it should first be determined that the
exhaust system is not blocked, the engine is running
properly and the transm ission is in first (1st) gear when
starting out.
If the engine will free acclerate to high rpm in Neutral
(N), it can be assumed that the engine and exhaust
system are normal.
If the stator assembly remains locked up at all times,

the engine rpm and vehicle speed will tend to be limited
or restricted at high speeds. The vehicle performance
when accelerating from a standstill will be normal. Engine
overheating may be noted. Visual examination of the
converter may reveal a blue color from the overheating
that will result.
DIAGNOSIS OF TORQUE CONVERTER CLUTCH (TCC)

To properly diagnose the Torque Converter Clutch
(TCC) system perform all electrical testing first and then
the hydraulic testing.
TORQUE CONVERTER CLUTCH (T.C.C.)

ELECTRICAL DIAGNOSIS
MECHANICAL CHECKS, SUCH AS LINKAGE, OIL LEVEL, ETC.,
SHOULD BE PERFORMED PRIOR TO USING THIS CHART.
Figure 8TCC Diagnosis
THM 400 PRELIMINARY CHECKING
CAUTION: TOTAL RUNNING

TIME FOR THIS COMBINATION
NOT TO EXCEED 2 MINUTES.
CHECK ENGINE TIMING AND IDLE (See Section 6-C& 6-D.)
INSTALL OIL PRESSURE GAGE (FIGURE 30)
CONNECT TACHOMETER TO ENGINE
C H E C K O iL P R E S S U R E S IN F O L L O W IN G M A N N E R
1
2
3
4
5
6
7
8
RANGE
NORMAL
kPa
NORMAL
P.S.I.
NEUTRAL-BRAKES APPLIED
ENGINE AT 1000 RPM
379 TO 483
55TO 70
DRIVE IDLE-SET ENGINE

IDLE TO SPECIFICATIONS
414 TO 586
60 TO 85
DRIVE-BRAKES APPLIED
ENGINE AT 1000 RPM
414 TO 621
60TO 90*
931 TO 1103
135to 160*
655 TO 1034
95 TO 150*
621 TO 758
90TO 110
INTERMEDIATE OR LO-BRAKES
APPLIED ENGINE AT 1000 RPM
REVERSE-BRAKES APPLIED
ENGINE AT 1000 RPM
DRIVE-BRAKES APPLIED
ENGINE AT 1000 RPM
DOWNSHIFT SWITCH ACTIVATED
GOVERNOR CHECKFOR UPSHIFT iPROBLEM
DRIVE-30 MPH-CLOSED THROTTLE
ON ROAD, OR ON HOIST**
OIL PRESSURE PATTERN

LOW-NORMAL-HIGH
DROP OF
DROP OF 69
PSI OR MORE 10 PSI OR MORE
379 TO 483
55TO 70
* IF HIGH LINE PRESSURES ARE EXPERIENCED, REFER TO CAUSES OF HIGH LINE PRESSURE IN THIS
SECTION.
** VEHICLE ON HOIST, DRIVING WHEELS OFF GROUND, SELECTOR IN DRIVE, BRAKES RELEASED, RAISE
ENGINE TO 3000 R.P.M., CLOSE THROTTLE AND READ PRESSURE BETWEEN 2000 AND 1200 R.P.M.
B-08660
Figure 9Preliminary Checking Procedure

7. Place the selector in Reverse and check for reverse
operation.
Figure 10THM 400 Pressure Tap Location

ROAD TEST
1. Connect a portable tachometer to the engine. Engine
rpm will identify the shift points.
2. Place the selector in Drive position and accelerate
the vehicle from a rest at a minimum throttle opening.
The specifications for the shifts points are:
Downshifts should occur (3-2 and 2-1) as the ve
hicle speed decreases to 0 mph. Stop the vehi
cle.
3. Place the selector in Intermediate position and ac
celerate the vehicle from a rest. A 1-2 shift should oc
cur at all throttle openings. No 2-3 shift can be
obtained in this range. Stop the vehicle.
4. Place the selector in Low . No upshift should occur in
this range regardless of the throttle opening.
5. Position the selector in Drive and accelerate the ve
hicle to 35 mph and move the selector to Intermedi
ate . A 3-2 downshift should occur, increasing the
engine rpm and an engine braking effect should be
noticed on deceleration.
6. With the selector in Intermediate at approximately 25
mph, but not over 40 mph, at closed throttle, move the
selector to Low. A 2-1 downshift should occur, in
creasing the engine rpm and an engine braking effect
should be noticed on deceleration. Stop the vehicle.
UPSHIFT
MINIMUM
1-2
2-3
15 MPH
30 MPH
UPSHIFT
MAXIMUM
1-2
2-3
44-48 MPH
77-83 M PH
DETENT DOWNSHIFT
MINIMUM
3-2
2-1
68-73 MPH
28-32 MPH
B-08325
Figure 11THM 400 Shift Points
CAUSES OF LOW LINE PRESSURE

1. Low transmission oil level.
2. Modulator Assembly.
3. Filter.
Blocked or restricted. (There is no approved
service procedure for checking or cleaning the
filter. If the filter is suspected or being plugged or
restricted, it must be replaced).
Seal on intake pipe and/or grommet omitted or
damaged.
Split or leaking intake pipe.
Wrong filter assembly.
4. Pump.
Pressure regulator or boost valve stuck.
Gear clearance, damaged, worn. (Pump will
become damaged if drive gear is installed
backwards, or if converter pilot does not enter
crankshaft freely).
Pressure regulator spring, too week.
Not enough spacers in pressure regulator.
Pump to case gasket mispositioned.
Malfunctioning pump body and/or cover.
Mismatched pump cover/pump body.
5. Internal circuit leaks.
Forward clutch leak (pressure normal in neutral
and reverse-pressure low in drive).
Check pump rings.
Check forward clutch seals.
Direct clutch leak (pressure normal in neutral,
low, intermediate, and drive-pressure low in
reverse).
Check center support oil seal rings.
Check direct clutch outer seal for damage.
Check rear servo and front accumulator
pistons and rings for damage or missing.
6. Case assembly.
Porosity in intake bore area.
Check case for intermediate clutch plug leak or
missing plug.
Lo-reverse check ball mispositioned or missing
(this will cause no reverse and no overrun
braking in Lo range).
CAUSES OF HIGH LINE PRESSURE
1. Vacuum leak.
Full leak (vacuum line disconnected).
Partial leak in the line from the engine modulator.
Improper engine vacuum.
Vacuum operated accessory leak. (Hoses,
vacuum advance, etc.).
2. Damaged modulator.
Stuck valve.
Water in the modulator.
Not operating properly.
3. Detent system.
Detent sw itch actuated (plunger stuck) or
shorted.
Detent wiring shorted.
Detent solenoid stuck open.
Detent feed orifice in the spacer plate blocked.
Detent solenoid loose.
DIAGNOSIS OF THM 400

1
3
Drive
Neutral
Malfunction
Brakes
Drive
Applied
Idle
Left
Brakes
Applied
1000 rpm
1000 rpm
Drive-R
Reverse
Brakes
Brakes
Applied
Applied
1000 rpm 1000 rpm
6
Drive Left
Brakes Applied
1000 rpm
Downshift
Switch Activated
Pressure Drop
Drive
Occurs while
30 mph
Engine rpm
Closed
Possible Cause
Increases from
Throttle
of Malfunction
1000 to 3000 rpm

W heels Free
Oil
Oil
Oil
Oil
Oil
Oil
Pressure
Pressure
Pressure
Pressure
Pressure
Pressure
Normal
Normal
Normal
Normal
Normal
Normal
to M ove*
Oil
Pressure
10 psi Drop
or More
M alfunction in
Normal
Control Valve
Assembly
M alfunction in
Normal
Normal
Normal
Normal
Normal
Normal
Less than
10 psi Drop
Normal
Governor or
Governor Feed
System
No 1-2 Upshift
a n d /o r Delayed
Upshift
Normal
High
High
Normal
Normal
High
Normal
Malfunction in
Detent System
M alfunction in
M odulator or
High
High
High
Normal
High
Vacuum Feed
System to
M odulator
Oil Leak in Feed
Slipping-Reverse
Normal
Normal
Normal
Normal
Low
Normal
Normal
System to the
Direct Clutch
Slipping-1 st Gear
Normal
Low to
Low to
Low to
Normal
Normal
Normal
High
Normal
Normal
Normal
Low to
Low to
Normal
Normal
Downshift with
Zero Throttle
and No Engine
Downshifts
Forward Clutch
Stator and
Normal
Normal
High
Detent Wires
Switched
Braking in Drive
No Detent
Oil Leak in Feed

System to the
Normal
Normal
Normal
Normal
Normal
Low
Normal
M alfunction in
Detent System
*Drive range, vacuum line disconnected from modulator.

A dash ( - ) in the above chart means that the oil pressure reading has no meaning under the test condition.
Pressures obtained by the Preliminary Checking procedure
B-08741
Figure 12THM 400 Oil Pressure Check Chart
DIAGNOSIS OF THM 400
Figure 13No 1-2 Upshift and/or Delayed Upshift
DIAGNOSIS OF THM 400 (CONT.)
B-08737
Figure 1 4-1-2 Shift Feel Complaint Firm Shift

B-08735
Figure 1 5-1-2 Shift Feel Complaint Firm Shift
B-08336
Figure 1 6 -2 -3 Shift Complaint
B-08333
B-08324
Figure 19No Engine Braking Lo Range

1st Gear
Figure 17Drive In Neutral

Detent valve bore plug damaged.
Detent regulator valve pin short.
4. Pump.
Pressure regulator and/or boost valve stuck.
Incorrect pressure regulator spring.
Too many pressure regulator valve spacers.
Pump casting bad.
Pressure boost valve installed backwards or
malfunctioning.
CHECK O U TS ID E M A N U A L LINKAGE
CONTROL VALVE ASSEMBLYGOVERNOR LINE

PRESSURE CHECK
1.
2.
3.
4.
Install an oil pressure test gage.

Install a tachometer.
Disconnect the vacuum line to the modulator.
With the vehicle on a hoist driving wheels off the
ground, foot off the brake, in drive, check the line
pressure at 1000 rpm.
5. Slowly increase the engine rpm to 3000 rpm and
determine if a line pressure drop occurs (69 kPa [10
psi] or more).
6. If pressure drop of 69 kPa (10 psi) or more occurs,
disassemble, clean and inspect the control valve
assembly.
& C O RRECT
I
-
IN TE R N A L LINKAGE -
1. PAR K IN G BRAKE ROD A S S E M B L Y

(CHECK A C TU A TO R FOR C H A M FE R ).
2. PAR K IN G P A W L BR O K EN , C H A M FE R O M IT T E D .
3. PAR K IN G BRAKE B R ACKET LOO SE, B U R R OR
ROUGH EDGES OR IN C O R R E C TLY IN S T A L L E D
4. PAR K IN G P A W L R ETU R N S P R IN G M IS S IN G ,
BROKEN, IN C O R R E C LTY HOO KED.
5. BROKEN LU G S ON O U T P U T C A R R IE R .
B-08329
Figure 18Will Not Hold in Park or Will Not

Release From Park
Figure 20No Engine Braking Intermediate

Range 2nd Gear
B-08629
Figure 21No Reverse or Slips in Reverse

7. If the pressure drop is less than 69 kPa (10 psi):
Inspect the governor.
Stuck valve.
Weight freeness.
Restricted orifice in the governor valve.
Figure 22No 2-3 Upshift, 1st and 2nd Speeds Only
C heck the g ove rn or valve entry and

exhaust (0.50 mm [0.20-in.] min.).
Governor feed system.
Check the screen in the control valve
assembly or case.
Check for restrictions in the governor pipe.
Check for fit of the governor pipes in the
case holes.

B-08680
Figure 23No Drive in Drive Range
B-08675
Figure 24No Detent Downshift

NOTE: BEFORE C H E C K IN G T R A N S M IS S IO N FOR W H A T IS B E LIE V ED TO BE T R A N S M IS S IO N N O IS E , M A K E C E R TA IN TH E N O IS E IS
N OT FROM TH E W A T E R P U M P , G E N E R A TO R , A IR C O N D IT IO N E R , P O W E R S T E E R IN G , ETC. TH E SE C O M P O N E N T S CAN BE IS O L A T E D
BY R E M O V IN G TH E P R O P E R BELT A N D R U N N IN G TH E ENG IN E NO M O R E T H A N T W O M IN U T E S A T ONE T IM E .
B-08669
Figure 25Transmission Noisy
TRANSMISSION
181.
182.
185.
187.
188.
189.
2-3 S h ift Valve

G o v e rn o r
M a n u a l Valve
D e te n t P re ssu re R e g u la to r
1-2 A c c u m u la to r
F ile r
190.
191.
192.
193.
194.
195.
P re ssu re R e g u la to r
F ro n t S ervo
P re s s u re S w itc h
R ear Servo
3-2 S h ift Valve
D e te n t S o le n o id
7A-25
O il P u m p
O il C o o le r
S cre e n
M o d u la to r Valve
V a cu u m M o d u la to r
1-2 S h ift Valve
Figure 26THM 400 Oil Circuits

110.
170.
171.
177.
178.
180.
THM 400 CLUTCH PLATE APPLICATION CHART

FORWARD CLUTCH
NO. OF
FLAT STEEL
PLATES
MODELS
THICKNESS
2.32 MM
(.0915")
EV, FI, FS, HR, MA
FG, RC, RR, RT, RV, ZD, ZV
NO. OF
WAVED STEEL
PUTES
NO. OF
DISHED
PUTES
1.54 MM
(.0605")
1.37 MM
(.054")
1.97 MM
(.0775")
NO. OF
COMPOSITION
PUTES
5
1
4
ALL OTHERS
THM 400 CLUTCH P U TE APPLICATION CHART

DIRECT C LUTCH
NO. OF
F U T STEEL
PUTES
MODELS
THICKNESS
2.32 MM
(.0915")
FA, FB, FC, FD, FF, FJ, FK, FM
NO. OF
WAVED STEEL
PUTES
NO. OF
DISHED
PUTES
1.54 MM
(.0605")
1.37 MM
(.054")
1.97 MM
(.0775")
NO. OF
COMPOSITION
PUTES
FN. FP, FR, FT, FV, FW, FX, FZ

FG, ZD, ZV
EV, FT, FS, HR, MA, RV
FL, FQ, HZ, RC, RR
LR, LS
RT
5
6
THM 400 CLUTCH P U T E APPLICATION CHART

INTERMEDIATE CLUTCH
MODELS
THICKNESS
EV, FG, FI, FS, HR, MA
NO. OF
F U T STEEL
PUTES
NO. OF
WAVED STEEL
PUTES
2.51 MM
(.099")
1.74 MM
(.0685")
RV, ZD, ZV
A LL OTHERS
NO. OF
COMPOSITION
PUTES
F-02663
Figure 27THM 400 Clutch Usage Chart

AL
A A . Drive
AB. M o d u la to r
O r In te rm e d ia te
AC. To C o o le r
AD. From C o o le r
AE. B re a th e r
AF. L u b ric a tio n
AG. V e n t
AH
AA
AB
AP
AG
A H . Lin e
AJ. P ressure
R e g u la to r Feed
AK . C o n ve rte r
AL. Intake
A M . E xh au st
AN . Reverse
B-08635
Figure 28THM 400 Pump Cover Oil Passages
AA.
AB.
AC.
AD.
AG.
AH.
AK .
AL.
AN .
AO.
AN
Drive
M o d u la to r O r In te rm e d ia te
To C o o le r
From C o o le r
V e nt
Line
C o n ve rte r
Intake
Reverse
Seal Drain B ack H ole
AA. Drive
AB. M o d u la to r
O r In te rm e d ia te
AC. To C o o le r
AD. From C o o le r
AG. V e n t
AH.
AL.
AN .
AP
Line
Intake (Pum p)
Reverse
In te rm e d ia te
C lu tc h C up Plug
B-08630
Figure 30THM 400 Case Oil Passages
B-08641
Figure 29THM 400 Pump Body Oil Passages
Figure 31THM 400 Center Support Oil Passages
AA.
AH .
AM .
AN.
AQ.
AR.
AS.
AT.
AU.
AV.
AW.
AX.
AY.
185.
Drive
Line
E xh a u st
Reverse
D ire ct C lu tc h
In te rm e d ia te
Servo
D etent
M o d u la to r
G o ve rn o r
Lo
1 -2 A c c u m u la to r
Void
M anual Valve
B-08322
Figure 32THM 400 Valve Body Oil Passages
(TO F SERVO)
AZ
AA.
AH .
AM .
AN .
AR.
AT.
AU.
AV.
AW.
AZ.
BA.
BB.
(EXH
D rive
L in e
E xh au st
Reverse
In te rm e d ia te
D eten t
M o d u la to r
G o ve rn o r
Lo
Rnd
3rd C lu tc h
2nd C lu tc h
2-3 DR OIL TO F. SERVO
(TO END OF MOD. VALVE)
[) 0AN AA(2-3)
OAU
AA (2 3)
(INT.)n
n
00
AN
CD
AN
O
O
AH
AZ OAR
A N
am
a t a
a
AUA
AUT
AT
AW
AW
O
(2ND CL FEED)
q OAN
u O aaq
an
am
AM
1 = 1
AW
^ ( 2 - 3 DR TO 2 n d CL)
L o nu n Uau
n*'
aa
AA
AT
AA
oJ
K
A % AH
AN
(TO 3RD CL '
AW
a \a
OAH
ah
(TO DETENT)
B-08320
Figure 33THM 400 Valve Body Spacer Plate (Typical)
AV
(FEED)
/
AV
(PRESSURE)
AA. D rive
AB. M o d u la to r o r In te rm e d ia te
AH.
AM .
AN .
AP.
AQ.
AR.
Lin e
E xh a u st
R everse
In te rm e d ia te C lu tc h
D ire c t C lu tc h
In te rm e d ia te
AS.
AT.
AU.
AV.
AW.
AX.
BC.
Servo
D eten t
M o d u la to r
G o ve rn o r
Lo
Reverse o r Lo
B-08323
Figure 34THM 400 Case Oil Passages (Bottom View)
THM 700-R4 PRELIM INARY CHECKING
CHECK TRANSMISSION OIL LEVEL

CHECK AND ADJUST T V CABLE
CHECK OUTSIDE MANUAL LINKAGE AND CORRECT
CHECK ENGINE TUNE
INSTALL OIL PRESSURE GAGE (FIGURE 57)
CONNECT TACHOMETER TO ENGINE
CHECK OIL PRESSURE AS FOLLOWS:
* NOTICE Total
running time for this
combination not to exceed 2 minutes.
CAUTION
Brakes must be
applied at all times.
Minimum T V Line Pressure Check

Set the T V cable to spe cifica tion; and w ith the brakes applied, take the line pressure readings in the ranges
and at the engine r.p .m .'s indicated in the cha rt below .
Full T V Line Pressure Check

Full T V line pressure readings are obtained by ty in g or holding the T V cable to the fu ll e xte n t o f its travel; and
w ith ,th e brakes applied, take the line pressure readings in the ranges and at the engine r.p .m .'s indicated in the
chart below.
AUTOMATIC TRANSMISSION OIL PRESSURES
Range
PARK,
NEUTRAL,
OVERDRIVE &
Normal Oil Pressure
Normal Oil Pressure
At M inim um T.V.
At Full T.V.
Model
kPa
PSI
kPa
PSI
Y L M ,Y T M
38 5 - 444
5 6 - 64
818-1040
119-151
YMM
4 5 1 - 515
6 6 -7 5
1115-1430
162-207
YXM
451-515
6 5 -7 5
840-1053
122-153
MCM, MHM, PAM, TAM, YFM, MTM, PRM, TNM, TRM, PGM, TBM
451-515
65-7 5
844-1068
122-155
451 -51 5
65-7 5
851-1063
123-154
TJM, TKM, M WM, MZM, TUM, TXM, FAM, MOM, MPM,

MAM, MSM, MMM, MRM, MXM, MKM, MUM
MANUAL 3RD
@ 1000 RPM
YPM
3 84-444
56-64
876-1333
127-193
YKM
3 84-444
56-64
883-1129
128-164
TSM
3 84-444
56-64
962-1237
139-179
YAM, YCM, YWM, YZM, YDM
3 84-444
5 6 -6 4
1049-1359
152-197
YTM
6 32-729
92-106
* 1345-1710
195-248
YMM
7 42-846
108-123
*1834-2351
266-341
YLM
632 -72 9
92-106
*1380-1782
200-258
YXM
742-847
108-123
*1381-1731
200-251
REVERSE
MCM, MHM, PAM, TAM, YFM, MTM, PRM, TNM,TRM, PBM, TBM
742-847
108-123
*1388-1755
201-254
@ 1000 RPM
TJM, TKM, MWM, MZM, TUM, TXM. FAM, MDM, MPM,
742-847
108-123
*1399-1747
203-253
YPM
632 -73 0
92-106
*1441-2191
209-318
YKM
632-730
92-106
*1452-1856
211-269
TSM
632-730
92-106
*1581-2034
229-295
2000
RPM
MANUAL 2ND
& MANUAL L0
M AM, MSM, MMM, MRM, MXM, MKM, MUM
YAM, YCM, YWM, YZM, YDM
632 -73 0
92-106
*1724-2234
250 -32 4
TSM, YAM, YCM, YKM, YLM, YPM, YTM, YWM, YZM, YDM
1120-1293
162-187
1120-1293
162-187
1127-1286
163-186
1127-1286
163-186
FAM, MCM, MDM, MHM, MPM, PAM, TAM, YFM, YMM, YXM, MAM, MSM, MMM, MRM,
@ 1000 RPM MXM, MTM, PRM, MKM, MUM, TJM, TKM, TNM, TRM, MWM, MZM, TUM, TXM, PBM, TBM
Line pressure is basically controlled by pump o u tp u t and the pressure regulator valve. In addition, line pressure
is boosted in Reverse, Second and Lo by the reverse boost valve.
A lso , in the Neutral, Drive, Interm ediate and Reverse positions o f the selector lever, the line pressure should increase
w ith th ro ttle opening because of the T V system . The pressure is controlled by the T V cable, the th ro ttle lever and
bracket assem bly and the T V link, as w ell as the control valve assem bly.
The main line pressure tap plug is located on the le ft side of the transm ission above the outside manual lever.
F-02664
Figure 35Oil Pressure Check Procedure
DIAGNOSIS OF THM 700-R4

9
o
IMPORTANT
A s a d ia g n o s is aid, you can c h e c k th e o il p re ssure d iffe re n tia l b etw e en lin e p re ssu re and th e
2nd, 3rd, and 4th c lu tc h p re ssure w h ile d riv in g th e v e h ic le . If th e p re ssure d iffe re n tia l b e
tw e e n lin e p re ssure and any o f th e c lu tc h c irc u its is m ore th a n 70 kPa (10 psi) (p ro vid e d y o u r
g ag es are accurate), th e re is a p o s s ib le leak in th a t c lu tc h o il c irc u it.
D
A.
B.
C.
D.
Line P ressure
T h ird P ressure
F o u rth P re ssure
S e con d P ressure
B-08331
Figure 36THM 700-R4 Pressure Tap Locations

ROAD TEST
Performthe road test following the sequence given.
KPH (MPH) shift points will vary with actual throttle
position and driver habits.
Compare the results of the test with speed shift chart
information. Use these results with the diagnosis
information to evaluate the transmission (figure 37).
This test should only be performed when traffic and
road conditions permit.
Observe all traffic safety regulations.
GARAGE SHIFT CHECK

1. Start engine.
2. Depress brake pedal.
3. Move gear selector:
Park (P) to Reverse (R).
Reverse (R) to Neutral (N) to Drive (D).
Gear selections should be immediate and not
harsh.
UPSHIFTS AND TORQUE CONVERTER CLUTCH (TCC)

APPLY
With gear selector in Overdrive (D).
1. Accelerate using a steady increasing throttle pressure.
2. Note the shift speed point gear engagements for:
2nd gear.
3rd gear.
Overdrive.
3. Note the speed shift point to TCC apply. This should
occur while inthird gear or overdrive. If the apply is not
noticed, refer to the Preliminary Torque Converter
Clutch Diagnosis information contained in this section
of the Service Manual.
Im portant
The torque converter clutch will not engage if engine
coolant has not reached a minimum operating
temperature of approximately 54C (130F).
PART THROTTLE DETENT DOWNSHIFT

At vehicle speeds of 40-55 MPH (64-88 KPH) quickly
depress the accelerator to a half open position and
observe:
TCC releases.
Transmission downshift to 3rd gear immediately.
FULL THROTTLE DETENT DOWNSHIFT

At vehicle speeds of 40-55 MPH (64-88 KPH) quickly
depress the accelerator to a wide open position and
observe:
TCC releases.
Transmission downshifts to 3rd gear immediately.
MANUAL DOWNSHIFT
1. At vehicle speeds of 40-55MPH (64to88 KPH) release
the accelerator pedal while moving the gear selector to
Third gear (D) and observe:
TCC release.
Transmission downshift to 3rd gear should be
immediate.
Engine should slow vehicle down.
2. Move gear selector to Overdrive (D) and accelerate to

40-45 MPH (64-72 KPH). Release the accelerator pedal
while moving the gear selector to Second gear (2)
and observe.
TCC release.
Downshift to second gear should be immediate.
3. Move gear selector to Overdrive (D) and accelerate
to 25 MPH (40 KPH). Release the accelerator pedal
while moving the gear selector to First gear (1) and
observe:
TCC release.
Transmission downshift to 1st gear should be
immediate.
COASTDOWN DOWNSHIFT
1. With the gear selector in Overdrive (D) accelerate to
4th gear with TCC applied.
2. Release the accelerator pedal and lightly apply the
brake to observe:
TCC release.
Shift points for downshifts.
MANUAL GEAR RANGE SELECTION

MANUAL THIRD (D)
1. With vehicle stopped, place gear selector in Third
(D) and accelerate to observe:
The first to second gear shift point.
The second to third gear shift point.
MANUAL SECOND (2)

1. With vehicle stopped, place gear selector in Second
(2) and accelerate to observe:
The first to second gear shift point.
2. Accelerate to 25 MPH (40 KPH) and observe:
That a second to third gear shift does not occur.
That TCC does not engage.
MANUAL FIRST (1)

1. With vehicle stopped, place gear selector in First (1)
and accelerate to 15 MPH (24 KPH) and observe:
T h a t no u p s h ift occurs.
That TCC does not engage.
REVERSE
1. With vehicle stopped, place gear selector in Reverse
(R) and slowly accelerate to observe reverse gear
operation.
All possible throttle positions and corresponding MPH
shift point information has not been provided.

1987 THM 700-4R SPEED SHIFT CHART
Model
1-2
Min
Throt
2-3
Min
Throt
3-4
Min
Throt
4-3
Part
Throt
3-2
IPart
Throt
FAM
12-15
20-30
33-55 +
55 +
38-55 +
MDM
13-16
22-30
37-55 +
55 +
MHM
9-11
17-24
28-47
55 +
MPM
11-14
19-26
33-51
NTM
13-19
23-38
46-55 +
4-3
Coast
Down
3-2
Coast
Down
2-1
Coast
Down
28-54
17-28
11-14
42-55 +
32-55
19-27
12-14
27-45
25-44
14-22
8-10
55 +
37-55
28-49
16-24
10-13
55 +
44-55 +
38-55 +
19-31
12-17
PAM
9-11
17-24
28-47
55 +
27-45
25-44
14-22
8-10
TAM
9-11
15-22
23-51
55 +
27-51
20-47
11-20
8 -10
TSM
8-10
16-22
25-53
55 +
26-55
23-48
13-20
7- 9
YMM
9-10
13-19
24-44
55 +
22-52
18-38
10-16
8- 9
YTM
12-14
19-25
36-55
55 +
38-55 +
31-53
15-23
11-13
YWM
8- 9
12-17
24-44
55 +
23-53
19-39
9 -14
7- 9
YXM
10-12
16-27
35-52
55 +
36-54
30-49
13-23
9-11
YZM
11-13
13-24
34-46
55 +
10-20
30-44
10-20
13-24
YLM
10-12
16-23
32-37
55 +
31-47
28-45
12-19
16-23
YKM
10-12
19-25
31-48
55 +
31-52
27-45
15-23
19-25
YFM
11-14
18-25
31-54
55 +
28-51
26-51
15-23
10-13
YCM
11-12
15-22
32-55 +
55 +
30-55 +
24-51
12-18
9-11
YAM
9 -10
13-18
27-48
55 +
25-55 +
21-43
10-16
8- 9
YPM
11-13
19-26
28-43
55 +
35-55
25-41
16-24
10-12
NOTES:
1. All speeds indicated are in miles per hour. Conversion to KPH = MPH x 1.609
2. Shift points will vary slightly due to engine loads and vehicle options
3. Speeds listed with + exceed 55 mph
Figure 37THM 700-R4 Speed Shift Charts
F -0 2 6 6 5
AUTOMATIC TRANSMISSIONS7A-35
DIAGNOSIS OF THM 70O-R4

Oil Pressure High Or
Low
(Check With Gage Check Oil Level &
Engine Tune)
CORRECTION
POSSIBLE CAUSE
PROBLEM
2. Oil filter.
3.
4.
5.
6.
TV exhaust ball.
Throttle lever and bracket assembly.
Throttle link.
Valve body.
3.
4.
5.
6.
7. Case.
High Or Low Shift

Points
1.
2.
3.
4.
TV cable.
TV exhaust ball.
Throttle lever and bracket assembly.
Oil pump assembly.
5. Vaive body assembly.
1.
2.
3.
4.
Pressure regulator valve stuck.

P re ssure re g u la to r va lve s p rin g
damaged.
R o to r g u id e m is s in g or m isa ssembled.
Rotor cracked or broken.
TV valve, reverse boost valve or
bushing stuck, damaged or incor
rectly assembled.
O rifice hole in pressure regulator
valve plugged.
S tickin g slide or excessive rotor
clearance.
Pressure relief ball not seated or
damaged.
Porosity in pump cover or body.
Wrong pump cover.
Pump faces not flat.
Intake pipe restricted by casting
flash.
Cracks in filter body or intake pipe.
Seal missing, cut or damaged.
Stuck or damaged.
Misassembled, binding or damaged.
a. Manual valve scored or damaged.
b. Spacer plate or gaskets incorrect,
misassembled or damaged.
Face not flat.
Throttle valve sticking.
Throttle valve sleeve rotated in bore
or retaining pin not seated.
TV lim it valve sticking.
Modulated downshift vaive stuck.
Line bias valve stuck.
2-3 shift valve stuck.
C h e c k b a lls m is s in g o r m is a s
sembled.
Case to valve body face not flat.
Binding or not correctly adjusted.

Stuck or damaged.
a. Stuck pressure regulator valve or TV
boost valve,
b. Sticking pum p slide.
5. a. Sticking throttle valve or plunger.
b. Modulated TV up or down valves
sticking.
c. TV limit valve sticking.
d. S p ace r plate or gaskets m isas
sembled, dam aged or incorrect.
DIAGNOSIS OF THM 700-R4 (CONT.)

PROBLEM
1st Gear Range Only
POSSIBLE CAUSE
1. Governor assembly.
No Upshift
2. Valve body.
3. Case.
4. 2-4 servo assembly.
5. 2-4 band assembly.
Slips In 1st Gear
1. Forward clutch assembly.
2. Input housing and shaft assembly.

3. Valve body.
4. TV cable.
CORRECTION
1. a. Governor valve sticking.
b. Governor driven gear loose or dam
aged.
c. Governor driven gear retaining pin
missing.
d. Nicks or burrs on output shaft.
e. Nicks or burrs on governor sleeve or
case bore.
f. Governor support pin in case too
long or short.
g. Governor weights or springs miss
ing binding or damaged.
2. a. 1-2 shift valve sticking.
b. Spacer plate or gaskets mispositioned or damaged.
3. a. Case to valve body face not flat or
damaged,
b. Governor screen restricted or dam
aged.
4. a. Restricted or blocked apply pas
sages in case.
b. Nicks or burrs on servo pin or pin
bore in case.
c. Missing or dam aged piston or pin
seals.
d. 4th servo piston in backwards.
5. a. 2-4 band worn or damaged.
b. Band anchor pin not engaged.
1. a. Clutch plates worn.
b. Porosity or dam age in forward clutch
piston.
c. Forward clutch piston inner and
outer seals m issing, cut or dam
aged.
d. Input h ousing to forw ard clu tch
housing seal missing, cut or dam
aged.
e. Damaged forward clutch housing.
f. Forward clutch housing retainer and
ball assembly not sealing or dam
aged.
2. Turbine shaft seals m issing, cut or
damaged.
3. a. Accum ulator valve stuck.
b. Face not flat, dam aged lands or in
terconnected passages.
c. Spacer plate or gaskets incorrect,
m ispositioned or damaged.
4. Binding or broken.
AUTOMATIC TRANSMISSIONS 7A-37

PROBLEM
Slips In 1st Gear
(Continued)
5. 1-2 accum ulator piston assembly.
6. Oil pressure.
1-2 Shift Speed

High Or Low
1. TV cable.
3. Throttle lever and bracket assembly.
4. Valve body.
5. Oil pump assembly or case.
Slipping Or rough 1-2

Shift
CORRECTION
POSSIBLE CAUSE
1. Throttle lever and bracket assembly.

5. a. Porosity in piston or 1-2 accum ulator

cover and pin assembly.
b. Damaged ring grooves on piston.
c. Piston seal missing, cut or dam
aged.
d. 1-2 accum ulator cover gasket miss
ing or damaged.
e. Leak between piston and pin.
f. Broken 1-2 accumulator spring.
6. Refer to Causes of High or Low Oil
Pressure.
7. 4th servo piston in backwards.
1. a. Binding or broken.
b. Not correctly adjusted.
2. Refer to 1st Gear Range Only No
Upshift.
3. a. M isa ssem b le d, b in din g or d am
aged.
b. TV link missing, binding or dam
aged.
4. a. TV exhaust check ball stuck.
b. TV plunger sticking.
c. Face not flat.
5. Face not flat.
1. a.
b.
2. a.
b.
c.
d.
3. 2-4 service assembly.
3.
4. 2nd Accumulator.
4.
5. 2-4 band.
6. Oil pump assembly or case.
5.
6.
Incorrectly installed or damaged,

TV cable broken or binding.
Throttle valve sticking.
TV bushing turned in its bore.
1-2 shift valve train stuck.
Gaskets or spacer plate incorrect,
mispositioned or damaged.
e. Line bias valve stuck.
f. Accum ulator valve stuck.
g. TV limit valve stuck.
h. Face not flat.
a. Apply pin too long or too short.
b. Servo seals missing, cut or dam
aged.
c. Restricted or missing oil passages.
d. Servo bore in case damaged.
a. Porosity in 1-2 accumulator housing
or piston.
b. Piston seal or groove damaged.
c. Nicks or burrs in 1-2 accum ulator
housing.
d. Missing or restricted oil passage.
Worn or mispositioned.
Faces not flat.

PROBLEM
No 2-3 Shift Or 2-3
Shift Slipping, Rough
Or Hunting
POSSIBLE CAUSE
1. Converter.
3. Oil pump.
4. Valve body.
5. Input housing assembly.
6. Case.
No. 3-4 Shift/Slipping

Or Rough 3-4 Shift
1. Governor.
CORRECTION
1. Internal damage.
2. a. Valve stuck.
b. Drive gear retaining pin missing or
loose.
c. Governor weights binding.
d. Governor drive gear damaged.
e. Governor support pin in case too
long or too short.
3. Stator shaft sleeve scored or off loca
tion.
4. a. 2-3 valve train stuck.
b. Accum ulator valve stuck.
c. Spacer plate or gaskets incorrect,
d. Throttle valve stuck.
e. TV limit valve stuck.
5. a. Clutch plates worn (3-4 or forward).
b. Excessive clutch plate travel.
c. Cut or damaged piston seals (3-4 or
forward).
d. Porosity in 3-4 clutch housing or pis
ton.
e. 3-4 piston check ball stuck, dam
aged or not sealing.
f. Restricted apply passages.
g. Forward clutch piston retainer and
ball assem bly not seating.
h. Sealing balls loose or missing.
6. 3rd accum ulator retainer and ball as
sembly not seating.
7. a. 2nd apply piston seals missing, cut
or damaged.
b. Servo pin seals missing, cut or dam
aged.
1. a. Governor weights binding.
b. Governor valve stuck.
c. Governor drive gear retaining pin
missing or loose.
d. Governor drive gear damaged.
e. Governor support pin in case too
long or too short.
2. a. Faces not flat.
b. Pump cover retainer and ball as
sembly m issing or damaged.

POSSIBLE CAUSE
PROBLEM
No 3-4 Shift/Slipping
Or Rough 3-4 Shift
(Continued)
3. Valve body assembly^
5. Case.

7. 2-4 band assembly.
No Reverse Or Slips
In Reverse
2. Manual linkage.
CORRECTION
3. a. Valves stuck.
-2 -3 shift valve train.
-A ccum ulator valve.
-T h rottle valve.
-T V limit valve.
-1-2 shift valve train.
-3 -2 control valve.
b. Manual valve link bent or damaged.
c. Spacer plates or gaskets incorrect,
m ispositioned or damaged.
,4. a. Incorrect band apply pin.
b. Missing or damaged servo seals.
c. Porosity in pistons, cover or case.
d. Damaged piston seal grooves.
e. Plugged or missing orifice cup plug.
5. a. 3rd accum ulator retainer and ball
assembly leaking.
b. Porosity in 3-4 accumulator piston or
bore.
c. 3-4 accum ulator piston seal or seal
grooves damaged.
d. Plugged or missing orifice cup plug.
e. Restricted oil passage.
6. Refer to Slipping 2-3 Shift.
7. Worn or misassembled.
1. a. 3-4 apply ring stuck in applied posi
tion.
b. Forward clutch not releasing.
c. Turbine shaft seals missing, cut or
damaged.
2. Not adjusted.
3. a. Retainer and ball assembly missing
or damaged,
b. S ta to r s h a ft seal rin g s o r rin g
grooves damaged.
* c. Stator shaft sleeve scored or dam
aged.
d. Reverse boost valve stuck, dam
aged or misassembled.
e. Cup plug missing.
f. Restricted oil passage.
g. Faces not flat.
h. Converter clutch apply valve stuck.
4. a. 2-3 shift valve stuck.
b. Manual linkage not adjusted.
c. Spacer plate and gaskets incorrect,

PROBLEM
No Reverse Or Slips
In Reverse
(Continued)
POSSIBLE CAUSE
5. Reverse input clutch.
6. Lo and reverse clutch.
7. Case.
No Part Throttle Or
Delayed Downshifts
1. External linkage.
No Overrun Braking
Manual 3-2-1
1. External linkage.
CORRECTION
b. Reverse input housing and drum as
sembly cracked at weld.
c. C lutch plate retaining ring out of
groove.
d. Return spring assem bly retaining
ring out of groove.
e. Piston deformed or dished.
f. Seals cut or damaged.
g. Retainer and ball assem bly not seal
ing.
h. Restricted apply passage.
b. Clutch plate retaining ring mispositioned.
c. Porosity in piston.
d. Seals damaged.
e. Return spring assem bly retaining
ring m ispositioned.
f. Restricted apply passage.
7. a. Cover plate gasket missing or dam
aged.
b. Cover plate not torqued correctly.
c. Porosity.
1. Not adjusted.
2. a. Apply pin seal cut or damaged.
b. Servo cover retaining ring missing
or misassembled.
c. 4th apply piston dam aged or misas
sembled.
d. Servo inner housing damaged or
misassembled.
3. a. Governor weights binding,
b. Governor valve stuck.
4. a. Valves stuck.
-T h rottle valve.
-3 -2 control valve.
-T V modulated downshift.
b. TV sleeve turned in bore.
c. 4-3 sequence valve body channel
blocked.
d. #5 check ball m issing from valve
body. .
1. -Not adjusted properly.
2. a. Valves stuck.
-4 -3 sequence valve.
-T h rottle valve.
b. Check ball #3 mispositioned.
c. Spacer plate and gaskets incorrect,
damaged or m ispositioned.

POSSIBLE CAUSE
PROBLEM
No Overrun Braking
3. Input clutch assembly.
3. a. Turbine shaft oil passages plugged

or not drilled.
b. Turbine shaft seal rings damaged.
c. Turbine shaft sealing balls loose or
missing.
d. Porosity in forward or overrun clutch
position.
e. Overrun piston seals cut or dam
aged.
f. Overrun piston check ball not seal
ing.
1. Electrical.
1. a. 12 volts not supplied to transm is

sion.
b. Outside electrical connector dam
aged.
c. Inside electrical connector, wiring
harness or solenoid damaged.
d. Electrical short (pinched solenoid
wire).
e. Solenoid not grounded.
f. In c o rre c t or d a m a g e d p re s s u re
switches.
2. Internal damage.
3. a. Converter clutch apply valve stuck
or assembled backwards.
b. Converter clutch apply valve retain
ing ring mispositioned.
c. Pump to case gasket m ispositioned.
d. Orifice cup plug plugged.
e. Solenoid 0 ring seal cut or dam
aged.
f. Orifice cup plug omitted from cooler
in passage.
g. High or uneven bolt torque (pump
body to cover).
4. Valves stuck.
-C onverter clutch shift valve.
-T h rottle valve.
5. a. Turbine shaft 0 ring seal cut or
damaged,
b. Turbine shaft retainer and ball as
sembly plugged.
Manual 3-2-1
(Continued)
No Converter Clutch
Apply
2. Converter.
5. Input housing and shaft.
Converter Shudder
CORRECTION
1. Torque converter assembly.

2. Valve body.
4. Oil filter.
1. Internal damage.
2. Converter clutch shift valve stuck.
3. a. Converter clutch apply valve stuck,
b. Restricted oil passage.
4. a. Crack in filter body.
b. Flash restricting filter neck.
c. Seal cut or damaged.

PROBLEM
Converter Shudder
(Continued)
POSSIBLE CAUSE
5. Miscellaneous.
6. Input housing and shaft assembly.
CORRECTION
5. a.
b.
6. a.
b.
Low oil
Engine
Turbine
Turbine
sembly
pressure.
not tuned properly.
shaft seal cut or damaged,
shaft retainer and ball as
damaged.
No Converter Clutch
Release
1. Solenoid.
2. Converter.
1. External ground.
2. Internal damage.
3. Converter clutch apply valve stuck.
Drives In Neutral
1. Forward clutch.
2. Manual linkage.
1. Not releasing.
2. a. Incorrectly adjusted,
b. Disconnected.
3. a. Face not flat.
b. Internal leakage.
3. Case.
2nd Gear Start (Drive

Range)
2. Forward sprag clutch.
No Park
Racheting Noise
Oil Out The Vent
1. Parking linkage.
Parking pawl.
1. Oil pump.
2. Valve body.
Vibration In Reverse
And Whining Noise In
Park
Oil pump.
1. a. Valve stuck.
b. Governor support pin too long or
missing.
2. Sprag assembly installed backwards.
1. a. Acutator rod assem bly bent or dam
aged.
b. Actuator rod spring binding or im
properly crim ped.
c. Actuator rod not attached to inside
detent lever.
d. Parking bracket dam aged or not
torqued properly.
e. Inside detent lever not torqued prop
erly.
f. Detent roller m ispositioned or not
torqued properly.
g. Parking pawl binding or damaged.
Parking pawl return spring weak, dam
aged or misassembled.
1. Chamfer in pump body rotor pocket too
large.
2. TV Imiit valve stuck.
Broken vane rings.
OIL AND WIRING CIRCUITS

TRANSMISSION
110.
170.
172.
173.
174.
175.
176.
180.
181.
182.
Oil Pump
Oil C ooler
TCC Solenoid
TCC Apply Valve
Line Pressure
Tap
3rd A ccum ulator
Pressure Tap
2nd C lutch
Pressure Tap
1-2 Shift Valve
Train
2-3 Shift Valve
Train
Governor
184. 3rd C lutch

Pressure S w itch
185. Manual Valve
188. 1-2 A ccum ulator
189. Filter
190. Pressure
Regulator
191. 2-4 Servo
192. 4-3 D ow nshift
S w itch
194. 3-2 Control Valve
Train
196. TCC Signal
S w itch
TRANSMISSION
197. TCC S hift Valve

Train
198. MTV Up Valve
Train
199. MTV Down Valve
Train
200. 3-4 S hift Valve
Train
201. 4th C lutch
Pressure Sw itch
202. 3-4 Relay Valve
203, 4-3 Sequence
Valve
TV
Plunger
204.
205. T hrottle Valve

(TV)
206. TV Exhaust Lifter
207. A ccum ulator
Valve Train
208. 3-4 A ccum ulator
209. TV Lim it Valve
Train
210. Line Bias Valve
Train
211. Pressure Relief
Valve
212. 4th C lutch
Pressure Tap
Check Balls
B-08461
Figure 38THM 700-R4 Oil Circuits
AA.
AB.
AC.
AD.
AE.
AF.
AG.
AH.
AJ.
AK.
AL.
AM .
AN .
AO.
A P.
AQ.
V ent
Lin e
Dec.
E xh au st
Rev. C lu tc h
D-2
MTV
3-4 C lu tc h
O.R. C lu tc h
Seal Drain
Void
Conv. C lu. Sig.
To C o o le r
Conv. C lu. Rel.
Lube
Conv. Feed
AM
AH AG
B-08601
Figure 39THM 700-R4 Pump Cover Oil Passages
AQ. Conv. Feed

AA.
A P.
AD.
AO.
AN.
AM.
AL.
AK.
AJ.
AH.
AG.
AF.
AE.
AB.
AC.
Vent
Lube
E xh a u st
Conv. C lu. Rel.
To C o o le r
Conv. C lu. Sig.
Void
Seal D rain
O.R. C lu.
3-4 C lu tc h
MTV
D-2
Rev. C lu tc h
Line
Dec.
Figure 40THM 700-R4 Pump Body Oil Passages
AR
AD.
AR.
AS.
AT.
220.
221.
222.
223.
224.
225.
226.
227.
228.
AS 220
E xh au st
4th Oil
3rd A c c u m u la to r O il
2nd Oil
Valve B ody Face
O il Pan Flange
Seal, 0 R ing (2-4 Servo Cover)
Cover, 2-4 Servo
P isto n , 4th S u p p ly
R ing, O il Seal O u te r (4th A p p ly P iston)
R ing, R e ta in e r (A p p ly Pin)
W asher, Servo A p p ly Pin
S p rin g, Servo A p p ly Pin
AT
229.
230.
231.
232.
233.
234.
235.
236.
237.
238.
239.
240.
241.
AD
221
Seal, O R ing
H o u s in g , Servo P isto n In ne r
R ing, O il Seal In n e r (2nd A p p ly P iston)
R ing, O il Seal O u te r (2nd A p p ly P iston)
P isto n, 2nd A p p ly
S p rin g, Servo C u s h io n
R etainer, Servo C u s h io n S p rin g
R ing, R e ta in e r (2nd A p p ly P iston)
Pin, 2nd A p p ly P isto n
Seal, 2nd A p p ly P is to n Pin
S p rin g, Servo R eturn
R etaine r & Ball A sse m bly, 3rd A ccu m .
Plug, C ase Servo
B-08561
Figure 41THM 700-R4 Servo Assembly

AE.
AF.
AU.
AV.
AW.
AX.
AY.
AS.
AZ.
AH.
AG.
AH.
BA.
AL.
BB.
AD.
AB.
BC.
AT.
BD.
AR.
AM.
BE.
BF.
AJ.
Reverse
D-2
Lo
Lo-1
D-4
G overnor
Lo Reverse
3 A ccum ulator
TV
3-4 C lutch
MTV
A ccum u la to r (4th) #1
4th Signal
Void
3-4 A ccu m u lato r
TV-Ex
Line
Part Throttle-D rive 3 *#3
2nd (1-2) #8
TVF
4th
Conv. Clu. Sig.
MTV Down
MTV Up
O.R. C lutch
AF
n . .
BH BJ AT BK AE A FAll AV AW AX
AR AZ B D ATBC ABADBB AL
Detent
Det./Lo ##9
3-4 C lutch (3-2 Ex.) #10
AH
BK. RND 4-3

Check Balls
B-08462
Figure 42THM 700-R4 Case Oil Passages and Check Ball Locations
BL.
AG.
AH .
AE.
AB.
AF.
BM .
Fw d. C lu tc h
M TV
3-4 C lu tc h
Reverse
Line
D-2
P re ssure Tap
AL.
AA.
BN.
AN.
AM .
AJ.
Void
V e nt
From C o o le r
To C o o le r
Conv. C lu. Sig.
O.R. C lu tc h
B-08465
Figure 43THM 700-R4 Pump Case Oil Passages
BP AD
AD.
BO.
BP.
BQ.
240.
241.
Servo E x h a u s t H ole
3rd A c c u m u la to r P re ssu re Tap Passage
2-4 Servo Bore
2nd & 4 th Band A p p ly P assage
R e ta in e r & Ball A s s e m b ly , 3rd A c c u m .
P lug, C ase Servo
y
B-08464
Figure 44THM 700-R4 Servo Oil Passages
AE
BK
6 '
\>
AE
o
AZ
BH
(------- OAU
V
^ O
CD
AS
AFO HAU
D#
A B *
A
u
&
C3
.w n
AB AV
AWO
o o ^
BG
AH AZ AG
#
BA
AX
BG
AG o
AW
BD
D ag Y ^ o
BB
AB.
AW.
AE.
AF.
AU.
AV.
AX.
AY.
AS.
AZ.
AG.
m o
BX
be
Oa
q ax
ax
o
BoF
AE
Q O Q

AB
AJ
Line
D4
Reverse
D2
Lo
Lo-1
Governor
Lo/Reverse
3rd A ccum ulator
TV
MTV
BR.
BA.
AT.
BB.
BD.
AJ.
AD.
BC.
BS.
BT.
Bolt Holes
A ccum ulator
4th Signal
2nd C lutch
3-4 A ccum ulator
TVF
Overrun C lutch
TV Ex.
DC3/Part Throttle
Part th ro ttle
D3
BB
r~\
/ lJ
BR(
BA
BU.
AM.
BF.
BE.
BG.
AH.
BH.
BK.
BX.
By.
4th C lutch
Conv. Clu. Sig.
MTV Up
MTV Down
Detent
3-4 C lutch
Detent/Lo
Rnd. 4-3
3rd C lutch
Id e n tifica tio n
B-08831
Figure 45THM 700-R4 Spacer Plate to Case Gasket
BK
AE
Q
A|J BG
O
ae
AF
AF
O
AB
AY
C D '
AW * 0
AE AX
a u
o a c3 AU
BH
AV
AZ
AT
BX
AXr
AX
ASD
QAE
AY
.AG
AH A Z ^ f
BX
BG
AW AX
BA
BG
op
AS
B0F BE
Qa u
AG
BB

AJ
AW
i ' ) C?
AB ^
BU
C3 o o
AT BS BT
AB.
AW.
AF.
AU.
AE.
AX.
AV.
AY.
AS.
AZ.
AG.
Line
D4
D2
Lo
Reverse
G o ve rn o r
Lo-1
Lo/R everse
3rd A c c u m u la to r
TV
MTV
BR.
BA.
AT.
BB.
BD.
AJ.
AD.
BC.
BS.
BT.
B o lt H o le s
A c c u m u la to r
4th S ig na l
2nd C lu tc h
TVF
O verrun C lu tc h
TV Ex.
D3/Part T h ro ttle
Part T h ro ttle
D3
BU.
AM .
BF.
BE.
BG.
AH .
BH.
BK.
BX.
BY.
4 th C lu tc h
Conv. C lu. Sig
MTV Up
MTV D ow n
D eten t
3-4 C lu tc h
D e te n t/L o
RND. 4-3
3rd C lu tc h
Id e n tific a tio n
B-08798
Figure 46THM 700-R4 Spacer Plate to Valve Body Gasket
GAS MODELS
ONLY
DIESEL MODELS
AF
o
AE
o
AZ
AU BG
O C>
i,
Q
AS
AU
r\
AV u
oa
BH AB
BX
AW AX
O
BA
AS
b e
BG
BB
AM
O U n
AB
^ H -B Y
gg
BU
AB
A_ ^ BS
ATC3 O OBT
AM
AB.
AW.
AF.
AU.
AE.
AX.
AV.
AY.
AS.
AZ.
AG.
> \>
B
0
u
Line
D4
D2
Lo
Reverse
G o ve rn o r
Lo-1
Lo/R everse
TV
MTV
BR.
BA.
AT.
BB.
BD.
AJ.
AD.
BC.
BS.
BT.
B o lt H o le s
A c c u m u la to r
4 th S ig n a l
2nd C lu tc h
TVF
O verrun c lu tc h
TV Ex.
D 3/Part T h ro ttle
Part T h ro ttle
D3
BU.
AM .
BF.
BE.
BG.
AH.
BH .
BK.
BX.
BY.
4 th C lu tc h
Conv. C lu. S ig n .
M TV Up
M TV D ow n
D e te n t
3-4 C lu tc h
D e te n t/L o
RND. 4-3
3rd C lu tc h
F-00910
Figure 47THM 700-R4 Spacer Plate (Typical)
nan1
AB.
AW.
AF.
AU.
AE.
AX.
AV.
AY.
AS.
Line
D4
D2
Lo
Reverse
G o verno r
Lo-1
Lo/Reverse
AZ.
AG.
BR.
BA.
AT.
BB.
BD.
AJ.
AD.
TV
MTV
A c c u m u la to r
4th S ignal
2nd C lu tc h
TVF
O verrun C lu tc h
TV Ex.
BC.
BS.
BT.
BU.
AM.
BF.
BE.
BG.
AH .
D3/Part T h ro ttle
Part T h ro ttle
D3
4th C lu tc h
Conv. C lu. Sig.
MTV Up
MTV Dow n
D etent
3-4 C lu tc h
BH.
BK.
BX.
BY.
AL.
AD.
BZ.
CA.
D e te n t/L o
Rnd. 4-3
3rd c lu tc h
Void
E xh a u st
SF
4-3
B-08520
Figure 48THM 700-R4 Valve Body Oil Passages
197
Or
AandB
INDICATES VALVE BORE BUSHINGS
------------------------P
A
205.
204.
203.
202.
209.
207.
210.
194.
185.
180.
T h ro ttle Valve (& B u sh in g )

T V P lu n g e r (& B u sh in g )
4-3 S e qu e nce Valve
3-4 Relay Valve
T V L im it Valve Train
A c c u m u la to r Valve Train
Line Bias Valve Train
3-2 C o n tro l Valve Train
M anual Valve
1-2 S h ift Valve Train
181.
200.
197.
198.
199.
A.

TCC S h ift Valve Train
M T V Up Valve Train
M T V D ow n Valve Train
C o n ve rte r C lu tc h T V B u s h in g Bore
P lug (ECM C o n tro lle d V e h icle s)
B. C o n v e rte r C lu tc h S h ift Valve Bore
P lug (ECM C o n tro lle d V e h ic le s )
Figure 49THM 700-R4 Valve Trains
B-08521

4-3SHIFT
(N.C.)
0.5 AMPS
+ 12V - 0.5 AMPS ! B
+12V
0.28 AMPSAD
+12V
TCC SOL
(N.O. OIL PATH
r _ n
4TH CL
(N.O.)
I
3RD CL
(N.O.)
TCC SIG
(N.O.)
NORMALLY OPEN (N.O.)

NORMALLY CLOSED (N.C.)
TYPE 1
MODELS: MD, MK, TK
Component
172. TCC S o le n o id
184. 3rd C lu tc h S w itc h
T erm in als
192. 4-3 S h ift S w itc h
T erm in als
196. TCC S ig n a l S w itc h
Term inal
201. 4th C lu tc h S w itc h
T erm in als
Color ID
W h ite
B lack/G reen D ot
Lt. Green
B la ck B ody
Yellow
B la ck
Lt. Green
B lack/G reen Dot
B lue
Wire
A. C o n n e c to r A To
4-3 S h ift S w itc h
B. C o n n e c to r B To
4th C lu tc h S w itc h
D. C o n n e c to r D To
3rd C lu tc h S w itc h
E. 4-3 S h ift S w itc h To
F. TCC S ig n a l S w itc h To
G. TCC S o le n o id To
Color ID
Red
W h ite
W h ite
W h ite
W h ite
Red
B-08516
Figure 50THM 700-R4 Wiring Type 1
4-3SHIFT
(N.C.
TCC_SOL_____
(N.O. OIL PATH)
0.5 AMPS
+12V
0.5 AMPS iB
+12V
4TH CL
D (N.O.)

NORMALLY CLOSED (N.C.
TYPE 2
MODELS: MF, MR, MX,
TC, TD, TF, TR
201
Component
Color ID
T erm inal
T erm in als
Y ellow
B la ck
Yellow
B la ck/G ree n D ot
B lue
Wire
E. 4-3 S h ift S w itc h To
G. TCC S o le n o id To
Color ID
Red
W h ite
W h ite
Red
B-08517
[T C C SOL
0 .5 A M P S I ( a 0 1 L P A T H ) I
+ 12 V
* p ^ n - i i
i4-3 SHIFT
i(N.C.)

TYPE 3
MODELS: TS, YF, YL,
MH, TN
Component
T erm in a ls
Color ID
B la ck
B la ck B ody
Yellow
Wire
G. TCC S o le n o id ( + ) To
Color ID
Red
Red
B-08513
4-3 PULSE
(N.C.) \
T C C S0L
(N.O. O IL PATH)
0.5 AMPS I
+ 12V
0.010 AMPS I B
+ 12V
^
GROUNDS
I
I_____V______________ J
4TH DISCREET
SW (N.C.)
172 i
TYPE 4
MODELS: FA, M A, M M , TJ,
YK, YN, YP, YT
Component
Term inal
201. 4th C lu tc h S w itc h *
Term inal
* O p tio n a l
Wire
Color ID
Red
B la c k B ody
Y ellow
M e ta llic /W h ite
B lue
M e ta llic /B la c k
TCC S o le n o id ( -) * *
**
Color ID
Red
W h ite
B la c k
Red
CCC G ro u n d
B-08512

4-3 S H IF T
T C C SOL
(N.O. OIL PATH)

0.5 AMPS i A
+ 12 V ->>
0.28 AMPS ,B
+ 12V
E.C.M.
GRD
3RD CL
(N.O.
(N.O.)
4TH CL

TYPE-5
5.0L GAS 2 W.D. (C) TRUCK
5.7L GAS 2 W.D. (C) &
4 W.D. (T) TRUCK
4.1L GAS 2 W.D. (C) TRUCK &
(G) VAN WITH EMISSION
SYSTEM FOR C ALIFO R N IA
C om ponent
T erm in als
T erm inals
196. TCC S ig na l S w itc h
Term inal
T erm in als
C o lo r ID
Blue
B lack/G reen D ot
Lt. Green
B la ck B ody
Yellow
B la ck
Lt. Green
B la ck
Blue
W ire
F. TCC S ig n a l S w itc h To
H. TCC S o le n o id (-) To
C o lo r ID
Red
W h ite
B la ck
W h ite
Red
B la c k
T.C.C. SOL
(N.O. O IL PATH)
---------- r
0.5 A M P S ^
+ 12 V ->>
---------
>B
G R O U N D ^ -----------------------i

TYPE 6
MODELS: MP, PL, TA, TB
Component
Color ID
Dk. Green
Wire
TCC S o le n o id ( + )
TCC S o le n o id (-)
Color ID
Red
B la c k
B-08510
Figure 55 THM 700-R4 W irin g Type 6

4TH CL
(NO.)
T C C SOL
(N O. OIL PATH)
0.5 AMPS
+ 12V
0.5 AMPS
+ 12V
0.28 AMPS
+ 12V
(NO.)

TYPE-7
2.0L GAS 2 W.D. (S) TRUCK WITH
EMISSION SYSTEM FOR HIGH
ALTITUDE U.S.A. EXCEPT CALIFORNIA
Component
196. TCC S ig n a l S w itc h
Term inal
T erm in als
Color ID
Gray
B la ck
Lt. Green
B la ck/G ree n Dot
B lue
Wire
TCC S ig n a l S w itc h
J. TCC S o le n o id To
Color ID
Red
Red
W h ite
Red
B-08509
T C C SOL
(N.O. OIL PATH)
0.5 A M P S' A
+ 12 V
0.010 AMPS 'B
+12 V
^
GROUND^
i
I
________ J
4TH DISCREET
SW (N.C.)
201
172

BC
TYPE 9
MODELS: YC, YD, YW, YX,
YZ, YA, YR, YS
Component
Term inal ( + )
201. 4th C lu tc h S w itc h *
Term inal
O p tio n a l
Color ID
O range
Red
Blue
Wire
TCC S o le n o id ( + )
TCC S o le n o id ( - ) * *
Color ID
Red
W h ite
B la ck
**C C C G rou nd
F-02666
T C C SOL
(N.O. O IL PATH)
215
0.5 AMPS I A
+ 12V
4 3 Sh ' f T
(N.C.)
E.C.M. G R D -y
*~ rh
4TH CL
(N.O.)
192

172 i
TYPE 10
MODELS: MW, TW
Component
Color ID
T e rm in a ls
Term inal
B row n
B la ck
Yellow
B la ck
Blue
Wire
A. C o n n e c to r A to
4-3 S w itc h
4 th C lu tc h S w itc h
4-3 S h ift
Color ID
Red
B la ck
F-02667
3RD CLU.
(N.O.)
4-3 SHIFT
(N.C.)
'1
+12V
0.5 AMPS
T C C SOL.
ECM
(N.O. O IL PATH)
GROUND>
fD

172
TYPE 14
MODELS: MC, MT, PR
Component
Color ID
T erm inals
T erm inals
Pink
B la ck/G ree n D ot
Lt. Green
B la ck B ody
Y ellow
Wire
TCC S o le n o id (-)
Color ID
Red
B la c k
F-02668
215
4-3 PULSE
(N.C.) \
T c c S0L
(N.O. O IL PATH)
\
|
0.5 AMPS
+ 12 V
0.010 AMPS I R
+ 12V
G R O U N D -^
I____ v____________ J
4TH DISCREET
SW (N.C.)
172
TYPE 4
MODELS: FA, M A, M M , TJ,
YK, YN, YP, YT
Component
T erm inal
201. 4 th C lu tc h S w itc h *
T erm inal
* O p tio n a l
Color ID
Red
B la ck B ody
Y ellow
B lue
Wire
TCC S o le n o id ( -) * *
Color ID
Red
W h ite
B la ck
Red
** C C C G ro u n d
F-02669
Figure 60 THM 700-R4 W irin g T ype 15
ON VEHICLE SERVICE
PARTS CLEANING, INSPECTION
AND REPLACEMENT
1. Use appropriate safety equipment such as:
Safety glasses.
Safety shoes.
Gloves.
2. Keep work area and tools clean.
3. Clean the transmission exterior before removing parts.
4. Do not use wipe cloths or rags.
5. Do not use solvents on:
Rubber seals.
Plastic/Teflon thrust washers.
6. Blow out all passages with compressed air.
7. Clean out small passages with fine wire.
8. Handle parts carefully to prevent damage.
9. Lubricate all internal parts with transmission fluid

during assembly.
10. When installing screws, bolts or studs into aluminum
always dip the threads in transmission fluid.
11. Always use a torque wrench for proper torque.
12. Recondition damaged or stripped aluminum threads
with thread inserts.
13. Replace all gaskets and seals.
Do not use gasket cement or sealers.
14. Replace Teflon and rubber lip seals only when
necessary and install them using the appropriate seal
protector.
Inspect
Manual linkage for:
Wear at pivoting points.
Bent or broken links and rods.

2. All seals, gasket and mating surfaces for:
Nicks.
Cuts.
Damage.
3. Snap rings for:
Expansion or compression.
Distortion.
Nicks.
Proper ring to groove fit.
4. Bearings and thrust surfaces for:
Wear.
Scoring.
Pitting.
OIL COOLER LINES

If replacement of transm ission steel tubing cooler lines
is required, use only double wrapped and brazed steel
tubing meeting GM specification 123M or equivalent.
Under no condition use copper or aluminum tubing to
rep la ce steel tu b in g . Those m ate ria ls do not have
satisfactory fatigue durability to withstand normal vehicle
vibrations. Steel tubing should be flared using the double
flare method.
COOLER LINE FLUSHING
In a major transmission failure, where particles of metal
have been carried with the oil throughout the units of the
transmission, it will be necessary to flush out the oil
cooler and connecting lines. To flush the oil cooler and
lines, use the following procedure:
1. Disconnect both cooler lines from the transmission.
2. Place a hose over the end of the cooler inlet line (from
the bottom of the cooler) and insert the hose into an
empty container.
3. Flush clean oleum solvent or equivalent through the
return line (from the top of the cooler) using an oil
suction gun until clean solvent comes out of the hose.
This will back flush the cooler.
4. Remove the hose from the inlet cooler line and place it
on the return line.
5. Flush clean oleum solvent or equivalent through the
inlet line until clean solvent comes out the return line.
R em ove re m a in in g s o lv e n t from c o o le r w ith
compressed air applied to the return line and flush with
transmission fluid.
6. Reconnect oil cooler lines and torque nuts to 17 N m
(12 ft. lbs.).
CHECKING AND ADDING FLUID

The automatic transmission is designed to operate at
the "F U LL HOT mark on the dipstick at normal operating
temperatures of 8 8 C -9 3 C (190F -200F ), and should
be checked under these conditions (figure 61).
The normal operating temperature is obtained only
after at least 24 km (15 miles) of highway type driving.
If the vehicle has recently been operated for an
extended period at high speed or in city traffic in hot
weather or the vehicle is being used to pull a trailer, an
accurate fluid level cannot be determined until the fluid
has cooled down, usually about 30 minutes after the
vehicle has been parked.
%$&&&i
A. O p e ra tin g Level
F-02670
Figure 61Transmission Dipstick

Inspect
1. Park vehicle on level ground.
2. Apply parking brake and block wheels.
3. Start engine and operate vehicle for 15 minutes or until
a normal operating temperature is reached.
4. Move gear selector through all gear positions.
5. Move gear selector to Park (P).
6. Check fluid level, color and condition. Refer to
Transmission Fluid Information in this section.
Important
DO NOT OVERFILL.
Overfilling can cause foaming and loss of fluid through
the vent. Slippage and transm ission failure can result.
Fluid level too low can cause slipping, particularly,
when the transm ission is cold or the vehicle is on a hill.
SHIFT LINKAGE
Apply the parking brake.
Retaining pin (226).
Rod (240) from the column lever.
Note the position of any washers, spacers and
insulators removed.
3. Rod (240) from the equalizer lever (238).
R, V and P Models.
Screw (242) and the washer.
Swivel (232).
G Models.
Nut (236), washers and the insulator.
Swivel (232).
Spacer and the retainer.
4. Retaining pin (227) and the equalizer lever (238).
Insulator, washer and the spring.
Clean
Metal parts using solvent. Wipe dry using a clean,
dry rag.
Rubber or nylon parts using soapy water. W ipe dry
using a clean, dry rag.

Equalizer lever (238) and a new retaining pin (227).
Spring, washer and the insulator.
226
227.
228.
228.
230.
231.
232.
233.
234
235.
236.
237.
238.
239.
R e ta in in g Pin
R e ta in in g Pin
N ut
S p rin g
W a sh e r
In s u la to r
S w ivel
R eta in e r
In s u la to r
S p rin g W a sh er
N ut
W asher
E q u a lize r Lever
S p a ce r
R V. P MODELS
229
240.
241.
242
243.
244.
A.
B.
Rod
W asher
G MODELS
Sc re vi
S p a ce '
240
In s u la to r
S h ift Lever
S te e rin g C o lu m n
239 /2 3 4
F-02671
Figure 62Shift Linkage

2. Rod (240) to the equalizer iever (238
R, V and P Models*
Swivel (232).
Washer and the screw (242)
G Models.
Retainer and the spacer
Swive! (232)
Insulator, washers anti the nut (236).
3. Rod (240) to the column lever
Insulators, spacers and washers i^ the positions
they were removed from.
4. New retaining pin (226).
A djust
1. Loosen the screw (242) or the nut (236), as used.
2. Put the column selector lever in the N (Neutral)
position.
Put the lever into the neutral gate, do not use the
indicator to find the neutral position.
3. Put the transmission in neutral.
tne shift ie^e- (A tc the rarwarc position,

the DacK tc the seconc aeienv (Figure 63).
Hold tne rod (240) tightly in the swivel (232)
Nut (236) o' the screw (242, tc 23 N m (17 ft.

lb.).
Put the column selector iever in the P (Park)
position
6. Check the adjustment
The column selector iever must go into all
positions
The engine must start in the P (Park) or N
(Neutral) positions only. Adjust if needed, refer to
Neutral Start Switch in this section.
CAUTION: With the selector lever in the Park

position, the parking pawl should freely engage
within the rear (reaction) internal gear lugs or
output ring gear lugs and prevent the vehicle
from rolling, which could cause personal injury.

1. Air cleaner.
2. Cable terminal (225) from the throttle lever (140).
3. C ab le h o u s in g (141) from
compressing locking tangs (B).
th e
b ra c k e t w h ile
4. Routing clips or straps.

5. Screw (252) and the washer.
6. Cable (142) from the transmission link (144).
Pull up on cable cover at the transmission until
the cable is visible.
7. Seal (254).

1. New seal (254) into the transmission case hole.
2. Cable (142) to the transmission link.
3. Screw (252) and the washer.
Align the indicator, if needed.
Release the parking brake.
Tighten
Screw (252) to 10 N m (7 ft. lbs.).
4. Cable routing clips or straps.
TV CABLE
The TV Cable used with the THM 700-R4 transmission
should not be thought of as an automatic downshift cable.
The TV cable used on the THM 700-R4 controls line
pressure, shift points, shift feel, part throttle downshifts
and detent downshifts. The function of the cable is sim ilar
to the combined functions of a vacuum modulator and a
detent cable.
The TV cable operated the TV link (144) and bracket in
the transmission (figure 64).
The TV b ra cke t a s s e m b ly se rve s tw o (2) b a s ic
functions:
1. The primary function of this assembly is to transfer the
carburetor throttle plate movement to the TV plunger in
the control valve assembly as related by the TV cable
and linkage. This causes TV pressure and line
pressure to increase according to engine throttle
opening and also controls part throttle and detent
downshifts. The proper adjustment of the TV cable is
based on the TV plunger being fully depressed to flush
with the TV bushing at engine wide open throttle.
2. The second function of the assembly involves a TV
exhaust ball. The function of this system is to prevent
the transmission from operating at low (idle position)
pressures, if the TV cable should become broken or
disconnected. If the cable is not connected or broken,
the TV lifter rod will not move from its normal spring
loaded up position which holds the TV exhaust check
ball off its seat. The TV lifter rod will drop down to allow
the TV exhaust ball to seat only if the cable if broken,
disconnected or extremely out of adjustment. With the
transmission pan removed, it should be possible to pull
down on the TV exhaust valve lifter rod and the springs
should return the rod to its normal up position. If the
throttle lever and bracket assembly or lifter rod binds or
sticks so that the TV lifter rod cannot lift the exhaust
ball off its seat, high line pressures and delayed shifts
will result.
5. Cable (142) through the engine bracket and engage

locking tangs (B) of the cable on the bracket.
Im portant
Avoid damaging or kinking the cable.
6. Cable terminal (255) to the throttle lever (140).
Pull on upper end of cable. It should travel a
short distance with light resistance caused by
the small return spring on the TV lever. When
releasing the upper end of the TV cable, it
should return to the zero TV position.
7. Adjust the TV cable. Refer to TV Cable Adjustment
in this section.
TV CABLE ADJUSTMENT
Adjustm ent of the TV cable must be made by rotating
the throttle lever at the carburetor or throttle body. Do not
use the accelerator pedal to rotate the throttle lever.
A djust (Figure 64)

1. Stop the engine.
2. Depress and hold down the metal re-adjust tab (250) at
the engine end of the TV cable (142).
3. Move the slider (251) until it stops against the fitting.
4. Release the readjustment tab (250).
5. Rotate the throttle lever (140) to its full travel
position.
6. The slider (251) must move (ratchet) toward the lever
when the lever is rotated to its full travel position.
Check that cable moves freely. The cable may
appear to function properly with the engine
stopped and cold. Recheck after the engine is
hot.
7. Road test the vehicle.
250
142
142
140
255
140.
141.
142.
144.
250.
251.
252.
253.
254.
255.
A.
B.
T h ro ttle Lever
C ab le H o u s in g
C able
L in k
R e -A d ju st Tab
S lid e r
S crew
W a sh er
Seal
T erm inal
ID N u m b e r
L o c k in g Tangs
Figure 64TV Cable (THM 700-R4)
CHANGING THE FLUID

AND FILTER
Raise the vehicle and support it using suitable safety
stands.
Place a drain pan under transmission oil pan.
1. Oil pan screws (222) from the front and sides only.
Loosen the rear oil pan screws approximately 4
turns.
NOTICE: Do not dam age the transmission case
or oil pan sealing surfaces.
2. Lightly tap the oil pan (221) with a rubber mallet or pry
down to allow the fluid to drain.
Inspect the fluid color, refer to Transmission
Fluid Information in this section.
3. Remaining oil pan screws (222), oil pan and the gasket
(220 ).
4. Oil filter (189) and the seal (223).
The seal may be stuck in the case.
Clean
Transmission case and oil pan gasket surfaces with
solvent and air dry.
All traces of old gasket m aterial must be
removed.
F-02702

3. Wire connector.
A djust (Figure 66)

1. Press the plunger (A) as far forward as possible.
2. Press the accelerator pedal to the floor.
VACUUM MODULATOR (THM 400)

I*"*! Remove or Disconnect (Figure 67)
Raise the vehicle.
1. Pipe (267) from the modulator port.
Hose.
2. Vacuum modulator (178).
Screw and the retainer.
Seal.
3. Pipe (267) if needed.
Hose.
Note the position of the pipe and any clips.
l y l Clean
- All parts using soapy water. Air dry.
}^\ Inspect
Modulator and pipe for kinks, cracks and damage.
Hoses for cracks, wear and dry rot.

Coat a new seal (223) with a small amount of
petrolatum.
1. New seal (223) onto a new filter (189).
2. New filter (189) into the case.
3. Oil pan (221) and a new gasket (220).
4. Screws (222).
Tighten
Screws (222) to 20 N m(15 ft. lbs.).
5. New transmission fluid.
Lower the vehicle.
Fill the transmission to the proper level with
DEXRON II fluid or equivalent. Refer to
Checking and Adding Fluid in this section.
Important
Do not overfill.
6. Check the oil pan gasket for leaks.
DETENT SWITCH (THM 400)
1. Pipe (267) if removed.

Seat the pipe against the manifold fitting.
The pipe must be routed in the position it was
removed from.
2. Vacuum modulator (178).
New seal.
Retainer and the screw.
3. Pipe (267) onto the modulator port.
Im portant
The pipe must not be twisted or bent.
4. Transmission fluid if needed. Refer to Checking and
Adding Fluid in this section.
SPEEDOMETER DRIVEN GEAR

VEHICLE SPEED SENSOR
1.
2.
3.
4.

Speedometer cable (277).
Screw and the retainer.
Sleeve and the seal.
Driven gear or speed sensor (280), as used.
U ] Inspect
1. Wire connector.
2. Screw.
3. Switch (260).

1. Switch (260).
2. Screw.
Gear teeth for nicks and burrs.

All parts for wear and damage.

1.
2.
3.
4.
Driven gear or speed sensor (280) as used.

New seal and the sleeve.
Retainer and the screw.
Speedometer cable (277).
178.
265.
266.
267.
268.
269.
270.
271.
V a cuu m M o d u la to r
M a n ifo ld F ittin g
H ose
P ipe
C lip
Seal
R e ta in e r
S cre w
B-08653
F igure 67Vacuum M o d u la to r (THM 400)

Release the parking brake.
1. Governor cover (287) and the seal or gasket as

used.
THM 700-R4
Tap around the cover flange with a punch.
GOVERNOR
THM 400

Raise the vehicle.
Lower the transm ission if needed for clearance,
refer to Transmission Replacem ent" in this section.
R em ove th e screw s.
Im portant
Do not damage the governor cover. If the cover
is damaged it must be replaced.
O r S peed S e n s o r
B-08637
Figure 68Speedometer Driven Gear
182.
285.
286.
287.
G o v e rn o r
Seal O r G a ske t (TH M 400 O nly)
S cre w (TH M 400 O nly)
G o v e rn o r C over
B-08676
Figure 69Governor
2 Governor (182).
jyj Clean
Governor using solvent. Air dry and blow out all
passages using dry compressed air.
Inspect
All parts for nicks, burrs, scoring and galling.
Governor sleeve for binding.
Governor valve for binding.
Driven gear for loose fit.
Weight springs for kinks or damage.
Weights for binding.
Valve entry opening. W ith the weights held all the
way outward, the opening should be 5.1 mm (0.020
in.) (Figure 70).
Valve exhaust opening. W ith the weights held all the
way inward, the opening should be 5.1 mm (0.020
in.) (Figure 71).
Figure 70Measuring the Governor Valve Entry

Opening
if the weights, sleeve, or valve do not operate freely,

disassem ble and clean the governor.
If the driven gear must be repiaced, the governor
must be disassembled.
Im portant
All the governor parts are a select fit. Except
for the driven gear, the governor m ust be
replaced as an assembly if repair is needed.
MDisassemble (Figures 72 and 73)

1. R em ove the governor w eight pins (310).
Cut off one end of each pin to remove them.
2. Remove the thrust cap (317), the weights (315 and 316)
and the springs (314).
3. Remove the valve (311) from the sleeve.
4. Remove the driven gear, if needed
Drive out the retaining pin using a punch or Vs in.
drill.
Figure 71Measuring the Governor Valve Exhaust

Opening
Figure 72Removing the Governor Weight Pins

Press the gear out of the sleeve using a punch,
with the gear supported in a press with two 2.778
mm (7/64 in.) plates in the exhaust slots.
5. Clean the governor parts and inspect for damage.
Assemble (Figures 73, 74 and 75)

1. New driven gear into the sleeve, if needed.
Press the gear in until it is almost seated using a
socket with the governor supported in a press
with two 2.778 mm (7/e4 in.) plates in the exhaust
slots.
Remove any shavings from the gear hub and
press the gear in until it is seated.
Drill a new pin hole 90 from the old one using a
1/s in. drill in a press.
312
310.
311.
312.
313.
314.
315.
316.
317.
W e ig h t P in s
Valve
R e ta in in g Pin
D riven G ear
S p rin g
P rim a ry W e ig h t
S e co n d a ry W e ig h t
T h ru s t C ap
Figure 73Governor Components
New retaining pin through the new pin hole so

the ends are just below the top of the hole.
Stake both ends of the pin hole in two places,
and wash the governor.
2. Valve (311) into the sleeve.
3. Springs (314), the weights (315 and 316) and the thrust
cap (317) onto the governor, aligning the pin holes.
4. New weight pins (310) and crimp both ends of each
pin.

1. Governor (182).
2. Governor cover (287) and a new seal or gasket as
used.
THM 700-R4.
Put a thin coat of Loctite Cup Plug Sealant
II, or equivalent, on the cover.
Tap the cover into place using a brass drift.
THM 400.
Screws.
Raise the transm ission if needed. Refer to
Transmission Replacement in this section.
B-08523
Figure 75Drilling the Driven Gear
Lower the vehicle.

2 -4 SERVO (THM 700-R4)

1.
2.
3.
4.
5.
Tool Required:
J-29714 Servo Cover Compressor.
Raise the vehicle.
Lower the transmission if needed for clearance. Refer
to Transmission Replacement in this section.
Retaining ring and the cover (223) using J-29714.
Seal from the cover.
4th apply piston (224).
2nd apply piston assembly (301).
Spring (239).
Disassemble (Figures 78 and 79)

Tool Required:
J-22269-01 Piston Compressor.
Housing (230) from the piston (233).
Seal from the housing.
2. Retainer ring from the pin (237).
Washer and the spring.
3. Pin (237).
Seals from the pin.
4. Retainer ring from the piston (233) using J-22269-01.
Retainer and the spring.
Seals from the piston.
Clean
All parts using solvent. Air dry.
Inspect
Pistons for porosity and damage.
Seal grooves for damage.
Cover for porosity and damage.
Seals for nicks and cuts and binding in the seal
grooves.
A.
222.
223.
224.
225.
229.
232.
238.
239.
300.
301.
C ase Servo Bore

Seal, O R ing (2-4 Servo Cover)
Cover, 2-4 Servo
P is to n , 4 th A p p ly
R ing, O il Seal O u te r (4th A p p ly P isto n )
Seal, O R ing
R ing, O il Seal O u te r (2nd A p p ly P is to n )
Seal, 2nd A p p ly P is to n R ing
S p rin g , S ervo R eturn
R ing, Servo C ove r R e ta in in g
2nd A p p ly P is to n A s s e m b ly
B-08536
Figure 7 7 -2 -4 Servo (THM 700-R4)
236
A. J -22269-01
233. Piston, 2nd Apply
236. Ring, Retainer (2nd A pply Piston)
B-08729
Figure 79Removing the Retainer Pin (THM 700-R4)
233
If damage is found, check for the cause of the

damage.
Springs for kinks and bending.
Pin for wear and burrs.
---------234
9
o
Im portant
C h e c k th e c a s e
s h a rp e d g e s .
s e rv o
b o re fo r d a m a g e
and
tp j Measure (Figures 80 and 81)

T o o ls R e q u ir e d :
J - 3 3 0 3 7 B a n d A p p ly P in T o o l
V e r n ie r c a lip e r s o r m ic r o m e t e r
1 . S e r v o p in le n g t h ( F ig u r e 8 0 ) .
In s t a ll p in a n d J - 3 3 0 3 7 a s s h o w n .
A p p ly 1 1 .0 N m ( 1 1 0 in . lb s .) t o r q u e a n d c h e c k t h e
g a g e s lo t (A ).
226.
227.
228.
229.
230.
231.
232.
233.
234.
235.
236.
237.
238.
Ring, Retainer (Apply Pin)

Washer, Servo A pply Pin
Spring, Servo A pply Pin
Seal, O Ring
Housing, Servo Piston Inner
Ring, Oil Seal Inner (2nd Apply Piston)
Ring, Oil Seal O uter (2nd Apply Piston)
Piston, 2nd A pply
Spring, Servo C ushion
Retainer, Servo C ushion Spring
Ring, Retainer (2nd A pply Piston)
Pin, 2nd Apply Piston
Seal, 2nd A pply Piston Pin
B-08530
2.
If t h e w h it e l in e is s e e n in t h e s lo t , t h e p in
is c o r r e c t .
If t h e w h it e l in e is n o t s e e n in t h e
r e p la c e t h e p in u s in g t h e c h a r t .
R e m o v e t h e p in a n d J - 3 3 0 3 7 .
P is to n a n d h o u s in g d im e n s io n (fig u r e 8 1 ).
M e a s u r e t h e p is to n d im e n s io n ( C ) .
M e a s u r e th e h o u s in g d im e n s io n (D ).
C h e c k th e c h a r t fo r th e p r o p e r d im e n s io n s .
Assemble (Figures 78 and 79)

Tool Required:
Jr22269-01 Piston Compressor
1. Retainer and the spring in the piston (233).
New seals on the piston.
Retainer ring using J-22269-01.
2. Pin (237).
New seals on the pin.
3. Retainer ring on the pin.
Spring and the washer.
Figure 782nd Apply Piston Assembly (THM 700-R4)
4. Housing (230) on the piston (233).

New seal on the housing.
s lo t,

2ND APPLY PISTON & HOUSING APPLICATION
MODEL
PISTON
DIMENSION
*A
HOUSING
DIMENSION
**B
YT, Y6, YK
63.10 mm
(2.48")
64.00 mm
(2.52")
YC, YX
44.64 mm
(1.78")
45.54 mm
(1.79")
ALL OTHERS
57.85 mm
(2.28")
58.74 mm
(2.31")
A. Gage Slot
B. J -33037
Pin Is Preset At Factory And M ust Not Be Re
adjusted
2-4 SERVO PIN SEL ECTION

PIN I.D.
PIN LENGTH
mm
INCH
66.37-66.67
67.74-68.04
69.11-69.41
2.61-2.62
2.67-2.68
2.72-2.73
2 Rings
3 Rings
W ide Band
B -0 8 7 3 1
Figure 80Measuring the Servo Pin Length

(THM 700-R4)
Important
B e
s u re
th e
p r o p e r s e a ls
a re
in
th e
p ro p e r
p o s itio n s (F ig u r e 7 7 ).
230. H ousing, Servo Piston (Inner)

233. Piston, 2nd A pply
-+ Install or Connect (Figures 76 and 77).
B -0 8 7 3 0
Figure 812nd Apply Piston and Housing

Dimensions (THM 700-R4)
J -2 9 7 1 4 S e rv o C o v e r C o m p re s s o r
1. S p rin g (2 3 9 ).
2 . 2 n d a p p ly p is to n a s s e m b ly ( 3 0 1 ) .
3 . 4 t h a p p ly p is to n ( 2 2 4 ) .
4 . N e w s e a l o n th e c o v e r.
J -2 1 4 2 6 E x te n s io n
(T H M 7 0 0 -R 4 )
5 . C o v e r ( 2 2 3 ) a n d t h e r e t a in in g r in g u s in g J - 2 9 7 1 4 .
R a i s e t h e t r a n s m is s io n if n e e d e d . R e f e r
T r a n s m is s io n R e p l a c e m e n t in t h is s e c t io n .
L o w e r t h e v e h ic le .

H o u s in g
O il
Seal
to
6 . T r a n s m i s s i o n f l u i d if n e e d e d . R e f e r t o C h e c k i n g a n d
A d d in g F l u i d in t h is s e c t io n .
REAR EXTENSION OIL SEAL

R a is e th e v e h ic le .
1 . T r a n s m is s io n flu id .
2.
P r o p e lle r s h a ft. R e fe r to P R O P E L L E R S H A F T (S E C .
4 A ).
3 . S e a l.
Figure 82Rear Extension Oil Seal
In s ta lle r

J-24057 Extension Housing and Pump Oil Seal
Installer (THM 400)
1. New seal using J-21426 or J-24057 as needed.
Coat the outer edge of the seal case with a non
hardening sealer.
4A).
Lower the vehicle.
3. New transmission fluid. Refer to Specifications for
the proper amount.
TRANSMISSION REPLACEMENT
19. S c re w s (2 2 6 ).
N o te th e lo c a tio n o f a n y
m o v e th e m a s id e .
S lid e
th e
tr a n s m is s io n
b r a c k e t s o r c lip s a n d
s tr a ig h t
T r a n s m is s io n c a s e u s in g a s o lv e n t d a m p e n e d c lo th ,
d o n o t a llo w s o lv e n t to e n t e r t h e t r a n s m is s io n . A ir
d ry .
A ll h a r d w a r e a n d f ly w h e e l c o v e r u s in g s o lv e n t . A ir
d ry .
A ll p a r t s f o r w e a r a n d d a m a g e .
A ll s e a ls a n d f it t in g s f o r s ig n s o f le a k a g e .
Tool Required:
6.
7.
J-21366 Converter Holding Strap

Air cleaner, and the TV cable fromthe throttle linkage,
if the transmission is being removed.
Raise the vehicle.
Transmission fluid.
Shift linkage.
Propeller shaft, refer to PROPELLER SHAFT (SEC.
4A).
Front propeller shaft, if used, from the transfer
case.
The support bracket at the catalytic converter.
Any other components as needed for clearance.
Support the transmission, and the transfer case,
if used, with a transmission jack.
Transmission crossmember.
Im portant
D o n o t s tr e tc h o r d a m a g e a n y c a b le s , w ir e s o r
o th e r c o m p o n e n ts
w h e n
lo w e r in g
th e
tr a n s m is s io n .
8 . T r a n s m is s io n fa r e n o u g h fo r c le a r a n c e to r e a c h o th e r
c o m p o n e n ts .
9 . D ip s t ic k t u b e ( 2 2 1 ) a n d t h e s e a l.
T o r q u e c o n v e r t e r fo r s tr ip p e d o r b r o k e n w e ld n u ts o r
s c r e w h o le s .
T r a n s m is s io n c a s e fo r p o r o s ity .

J -2 1 3 6 6 C o n v e r te r H o ld in g S tr a p
If t h e t r a n s m is s io n w a s l o w e r e d f o r c l e a r a n c e o n ly ,
d o s te p s 1 3 -2 0 .
1. T ra n s m is s io n (2 2 5 ).
B e s u r e t h e t o r q u e c o n v e r t e r is s e a t e d p r o p e r ly
a n d t h a t J - 2 1 3 6 6 is in p l a c e .
S u p p o r t th e tr a n s m is s io n , a n d t h e tr a n s f e r c a s e
if u s e d , w it h a t r a n s m is s io n j a c k .
R a is e t h e tr a n s m is s io n
J -2 1 3 6 6 .
S lid e t h e tr a n s m is s io n s tr a ig h t o n to t h e lo c a tin g
p in s (A ) w h ile lin in g u p t h e m a r k s o n t h e f ly w h e e l
a n d th e to rq u e c o n v e rte r.
C o v e r t h e o p e n i n g in t h e t r a n s m is s io n .
1 0 . S p e e d o m e te r c a b le .
11. V a c u u m
m o d u l a t o r l in e , if u s e d .
1 3 . C o o le r lin e s ( 2 2 3 ) .
C a p a ll o p e n in g s
lin e s .
th e
t r a n s m is s io n
it a s i d e ,
and
re fe r
to
N o te th e lo c a tio n o f th e ' b ra c e s , th e y m u s t b e
i n s t a l l e d in t h e s a m e p o s it io n s .
th e
fly w h e e l
re m o v e
T h e to r q u e c o n v e r te r m u s t b e flu s h
fly w h e e l a n d r o ta te fr e e ly b y h a n d .
o n to th e
2 . S c re w s (2 2 6 ).
A ll b r a c k e t s , c lip s a n d h a r n e s s e s m u s t b e in t h e
p o s itio n s th e y w e r e r e m o v e d fr o m .
D o n o t in s ta ll th e d ip s tic k tu b e
tr a n s m is s io n s u p p o r t b r a c e s c r e w s .
or
th e
and
S c r e w s fin g e r tig h t to in s u r e p r o p e r c o n v e r te r
s e a tin g .
S c r e w s to 6 5 N m ( 5 0 ft. lb s .).
R e m o v e th e e n g in e h o is t o r ja c k .
4 . C o n v e r te r h o u s in g c o v e r (2 2 8 ).
17. C o n v e r te r h o u s in g c o v e r (2 2 8 ).
M a rk
and
th e
1 5 . D a m p e n e r a n d t h e s u p p o r t , if u s e d .
1 6 . T r a n s m is s io n s u p p o r t b r a c e s (2 2 2 ).
p la c e
3. S c re w s (2 3 0 ).
in
1 4 . T r a n s fe r c a s e s h ifte r a n d m o v e
T R A N S F E R C A S E (S E C . 7 D ).
in to
Im portant
1 2 . E le c tr ic a l c o n n e c to r s fr o m t h e tr a n s m is s io n .
th e
Clean
Inspect
3.
4.
5.
o ff
2 0 . T r a n s m is s io n (2 2 5 ) fr o m th e v e h ic le .
If the transmission is being lowered for clearance, do

steps 1-8 only.
1.
2.
back
lo c a t in g p in s (A ) a n d in s t a ll J - 2 1 3 6 6 .
th e
to rq u e
c o n v e rte r
a lig n m e n t.
18. S c re w s (2 3 0 ).
Im portant
S u p p o r t t h e e n g in e w ith a ja c k o r h o is t b e fo r e
d is c o n n e c t in g t h e tr a n s m is s io n .
H o o k t h e c o v e r u n d e r t h e lip o f t h e e n g i n e o il
pan.
5 . T h e s u p p o r t a n d d a m p e n e r , if u s e d .
6 . T r a n s m is s io n s u p p o r t b r a c e s (2 2 2 ).
T h e b r a c e s m u s t b e in s ta lle d
th e y w e re re m o v e d fro m .
in t h e
p o s itio n s
7. T r a n s f e r c a s e s h if t e r , r e f e r to T R A N S F E R C A S E ( S E C .
7 D ).
232
220.
221.
222.
223.
224.
225.
226.
227.
228.
229.
230.
231.
232.
233.
Harness
Dipstick Tube
Support Brace
Cooler Lines
Seal
Transmission
Screws, Transmission To Engine
Exhaust Bracket
Converter Housing Cover
Flywheel
Screw, Flywheel To Torque Converter
Dampener
Insulator
Support
228
227
B-08535
Figure 83Transmission and Components (Typical)

8. Cooler lines (223).
Uncover the openings.
Do not twist or bend the lines.
9. Vacuum modulator line, if used.
10. Speedometer cable.
11. Electrical connectors to the transmission.
12. Dipstick tube (221) with a new seal.
Uncover the opening and install the seal first.
Screw (226).
13. Transmission into place.
Im portant
Do not pinch or damage any cables, wires or

other com ponents when raising the
transmission.
14. Transmission crossmember and the transmission

mount.
Any components that were removed for
clearance.
Remove the transmission jack.
15. The support bracket at the catalytic converter.
16. Propeller shaft, refer to PROPELLER SHAFT (SEC.
4A).
Front propeller shaft to the transfer case, if used.
17. Shift linkage.
Lower the vehicle.
18. New transmission fluid.
19. Air cleaner, and the TV cable, if removed.
SPECIFICATIONS
FASTENER TORQUE
Shift L in k a g e ............................................................................................................
TV Cable....................................................................................................................
Cooler Lines to Transm ission......................... .......................................................
Cooler Lines to R adiator.........................................................................................
Dipstick Tube to Alternator Bracket (G models)
Except with LBI E n g in e ...................................................................................
With LBI E n g in e ...............................................................................................
Transmission Support Braces
R and V M o d e ls ............................................................ ...................................
G Models (to E ngine)...... ............................ , . .................. ............................
(to Transmission)............................................................................
Dampener S upp ort........................................ .............................. ..........................
Dampener to S u p p o rt................................... ...................... ...................................
Converter Housing Cover
R and G Models Except with LBI Engine ................ . .................................
With LBI E n g in e ...............................................................................................
V Models
Except 30/3500 with L25 Engine...................................................................
30/3500 with L25 E ngine......................... .......................................................
P M odels...................................................... .....................................................
Transmission to E n g in e .................................................................. ........................
Converter to F lyw h e e l.............................................................................................
Crossmember to Frame
R, G and P Models...........................................................................................
V M odels............................................................................................................
Note:
LBI Engine - 4.3L (262 CID V6) Carbureted
L25 Engine - 4.8L (292 CID L6)
N-m
25
10
22
27
Ft. Lbs.
19
7
16
20
43
3.5
32
2.5
95
57
37
41
87
70
42
27
30
65
10
35
7
25
35
10
10
47
65
25
7
7
34.5
50
85
70
63
52
LUBRICATION
Capacity
Pan Removal
THM 400........................................................................ ........................ ..
THM 700-R4................................................................................................
Overhaul
THM 400.....................................................................................................
THM 700-R4................................................................................................
Type Recommended DEXRON II or equivalent
Note: DO NOT OVERFILL. Refer to Checking And Adding Fluid in this section.
4 I.
4.7 I.
9 pts.
10 pts.
10 I.
10.9 I.
22 pts.
23 pts.
SPECIAL TOOLS
1.
J-21366
2.
J-21426
5.
J-29714
3.
J-22269-01
6.
J-33037
1.
2.
3.
4.
5.
6.
J-24057
C onverter H olding Strap

E xtension H ousing Oil Seal In staller (THM 700-R4)
Piston C om pressor (THM 700-R4)
E xtension H ousing Oil Seal In staller (THM 400)
Servo Cover C om pressor (THM 700-R4)
Band A pply Pin Tool (THM 700-R4)
F-02673
MANUAL TRANSMISSION 7B-1
SECTION 7B
MANUAL TRANSMISSION
CONTENTS
SUBJECT
PAGE
Description.....................................................................................................................................................................7B- 1
Inspection.......................................................................................................................................................................7B- 1
Control Linkages.......................................................................................................................................................7B- 1
Transmission Shift E ffo r t........................................................................................................................................ 7B- 2
Diagnosis of Manual Transm ission............................................................................................................................7B- 2
On Vehicle S e rvice .......................................................................................................................................................7B- 3
Drian and F i l l .............................................................................................................................................................7B- 3
Rear Oil Seal...............................................................................................................................................................7B- 3
Speedometer Driven Gear........................................................................................................................................ 7B- 3
Shift L in k a g e .............................................................................................................................................................7B- 5
Shift Linkage A djustm ent.................................................................. ......................................................................7B- 6
Shift C ontrol...............................................................................................................................................................7B- 7
Side C o v e r.................................................................................................................................................................7B- 8
Transmission Replacement............... ....................................................................................................................7B-10
S pe cifica tio n s...............................................................................................................................................................7B-11
Fastener Torque.........................................................................................................................................................7B-11
L ub rication.................................................................................................................................................................7B-11
Special T o o ls .................................................................................................................................................................7B-12
DESCRIPTION
M a n u a l t r a n s m is s io n s a r e id e n tifie d b y : (A ) t h e n u m b e r
o f fo r w a r d g e a r s , a n d (B ) th e m e a s u r e d d is ta n c e b e tw e e n
c e n te r lin e s o f th e m a in s h a ft a n d th e c o u n te r g e a r .
T h e c o u n t e r s h a f t is n o t a p r e s s fit a n d is s e a l e d in t h e
fr o n t o f t h e c a s e w ith a n e x p a n s io n p lu g .
G e a r s h if t in g is d o n e w ith a f lo o r m o u n t e d s h if t c o n t r o l.
3-SPEED 76MM
4-SPEED 117MM
T h e t h r e e s p e e d M u n c i e 7 6 m m t r a n s m i s s i o n s ( R P O s
M 6 2 a n d M 6 4 ) a r e in c o n s t a n t m e s h a n d f u ll y
uses
s y n c h r o n iz e d
in
a ll f o r w a r d
sp eed s
s y n c h r o n iz e r s le e v e s .
G e a r s h if t le v e r s a r e e it h e r a
c o lu m n - t y p e s h ift le v e r .
w ith
flo o r -ty p e
tw o
or a
s lid in g
s te e r in g
T h e fo u r s p e e d M u n c ie 1 1 7 m m t r a n s m is s io n ( R P O M 2 0 )
a
c o n s ta n t
m esh
fir s t
g ear
and
s y n c h r o n iz e d
s e c o n d , th ir d a n d f o u r th g e a r s .
G e a r s h if t in g is d o n e w it h a t r a n s m is s io n c o v e r
m o u n t e d s h ift le v e r . T h e c o v e r h a s a b a ll p in t y p e in t e r lo c k
w h ic h s to p s t h e t r a n s m is s io n fr o m b e in g s h ifte d in to tw o
g e a r s a t o n e tim e .
4-SPEED O.D. 89MM

T h e fo u r s p e e d N e w P r o c e s s 8 9 m m t r a n s m is s io n ( R P O
M Y 6 ) is a n o v e r d r iv e u n it a n d is f u ll y s y n c h r o n i z e d in a ll
fo rw a rd s p e e d s .
INSPECTION
B e fo re
r e p a ir in g
th e
tr a n s m is s io n , c h e c k
th e
a n d s h iftin g lin k a g e s to b e s u r e t h e p r o b le m
c lu tc h
is in t h e
If a h y d r a u li c c lu t c h is u s e d , t h e r e a r e n o a d ju s t m e n t s
fo r lin k a g e o r c lu tc h p e d a l.
3 . C h e c k t h e s h ift lin k a g e fo r w o r n s w iv e ls ,
b ra c k e ts o r d a m a g e d c o rd o n s h a ft.
4 . C h e c k th e
n e c e s s a ry .
s h ift lin k a g e
a d ju s tm e n t a n d
m o u n tin g
a d ju s t a s
STEERING COLUMN SHIFT CONTROL
CONTROL LINKAGES
1. C h e c k th e c lu tc h
and
s h if t lin k a g e fo r d ir t, w e a r , o r
dam age.
2 . C h e c k c lu tc h f r e e p e d a l tr a v e l a d ju s t m e n t a n d a d ju s t
a s n e c e s s a r y . R e f e r to C L U T C H ( S E C .' 7 C ).
1. R e m o v e t h e s h ift c o n tr o l r o d s fr o m t h e c o lu m n le v e r s .
2 . C h e c k s h ift e f f o r t a t t h e s h ift c o n tr o l le v e r k n o b .
3 . If t h e e f f o r t is m o r e t h a n 9 N ( 2 lb .) , a d ju s t t h e s t e e r i n g
c o lu m n lo w e r b e a r in g . R e f e r to S T E E R IN G ( S E C . 4 B ).
4.
L u b r ic a t e a ll r o d a n d s w iv e l c o n n e c t io n s a n d r e c h e c k
s h ift e ffo r t.
7B-2 MANUAL TRANSMISSION

TRANSMISSION SHIFT
EFFORT
5 . If s h if t lin k a g e is f r e e f r o m b in d i n g , c h e c k f o r 0 .1 3 m m
( 0 .0 0 5 in .) e n d p la y b e t w e e n t h e c o lu m n le v e r s a n d
c o n tr o l le v e r .
6 . C o n n e c t th e c o n tr o l ro d s a n d c h e c k th e s te e r in g
c o lu m n c o n t r o l le v e r s f o r a l ig n m e n t . In n e u t r a l, t h e
c o lu m n c o n tr o l le v e r t a n g s s h o u ld lin e u p w ith t h e s lo t
in t h e r e l a y le v e r .
CLUTCH SPIN DOWN TIME

1 . R u n t h e e n g in e a t a n o r m a l id le w ith t h e t r a n s m is s io n
in n e u t r a l a n d t h e c l u t c h e n g a g e d .
2 . D is e n g a g e t h e c lu t c h , w a it n in e s e c o n d s a n d s h ift t h e
tr a n s m is s io n in to r e v e r s e .
3 . If a g r i n d i n g n o i s e is h e a r d , c h e c k t h e c l u t c h f o r t h e
p ro b le m . R e fe r to C L U T C H (S E C . 7 C ).
1. R e m o v e t h e s h ift r o d s a t t h e t r a n s m is s io n .
2 . L in e u p t h e p r o b le m g e a r b y s h if t in g in to t h e g e a r a n d
b a c k to n e u tr a l.
3 . C h e c k t h e e ffo r t n e e d e d to s h ift in to t h e p r o b le m g e a r
u s in g a t o r q u e w r e n c h .
4 . If t h e s h if t e f f o r t is m o r e t h a n 5 N m ( 5 0 in . l b s . ) a n d t h e
s h if t le v e r s h a f t is c l e a n a n d n o t d a m a g e d , a d d a n
a n t i- c h a t t e r lu b r ic a n t, (p o s itr a c tio n a d d itiv e ) to th e
5 . If t h e s h if t e f f o r t is s till h ig h , r e p a i r t h e t r a n s m is s io n a s
needed.
DIAGNOSIS OF MANUAL TRAN SM ISSIO N

T h e fo llo w in g d ia g n o s is in f o r m a t io n
1.
L u b r ic a n t le v e l to o h ig h .
2.
M a in d r iv e b e a r in g r e ta in e r o r g a s k e t
lo o s e o r d a m a g e d .
S id e c o v e r o r g a s k e t lo o s e o r d a m a g e d .
R e a r e x te n s io n s e a l d a m a g e d .
C o u n t e r s h a f t lo o s e in c a s e .
3.
4.
5.
Hard Shifting, Column

Shift Refer to
Transmission Shift
Effort 7B-2
1.
2.
Noisy Shifting
1.
2.
3.
Noisy Neutral
p r o b le m .
CORRECTION
POSSIBLE CAUSE
PROBLEM
Leaks Lubricant
is t o b e u s e d o n ly a s a g u i d e t o lo c a t in g a t r a n s m is s io n
1. D r a in to c o r r e c t le v e l.
2 . T ig h te n o r r e p la c e .
3.
T ig h te n o r r e p la c e .
4.
5.
R e p la c e .
R e p la c e c a s e .
L e v e r s b in d in g d ir ty o r d a m a g e d .
L e v e r e n d p la y m o r e th a n 0 .1 3 m m (0 .0 0 5
in .).
1.
2.
C le a n a n d lu b r ic a te o r r e p la c e .
A d ju s t. R e fe r to S T E E R IN G C O L U M N
(S E C . 3 B 4 ).
S h ift lin k a g e o u t o f a d ju s t m e n t o r d a m
1.
A d ju s t o r r e p la c e .
2.
A d ju s t o r r e p la c e . R e fe r
(S E C . 7 C ).
R e p a ir th e tr a n s m is s io n .
aged.
C lu tc h lin k a g e o u t o f a d ju s t m e n t o r d a m
aged.
S y n c h r o n iz e r s o r g e a r s w o rn o r d a m
aged.
3.
1.
S h ift lin k a g e o u t o f a d ju s t m e n t o r d a m
1. A d ju s t o r r e p la c e .
2.
3.
aged.
P ilo t b e a r in g w o r n o r d a m a g e d .
M a in d r iv e g e a r o r c o u n t e r g e a r b e a r in g s
2.
3.
R e p la c e . R e fe r to C L U T C H
R e p a ir th e tr a n s m is s io n .
1.
2.
3.
4.
5.
F ill to c o r r e
R e p la c e .
R e p a ir th e
R e p a ir th e
R e p a ir th e
1.
2.
R e p la c e .
A d ju s t o r r e p la c e .
to
C LU TC H
(S E C . 7 C ).
w o rn o r d a m a g e d .
Noisy Operation
Slips Out Of Gear
1.
L u b r i c a n t le v e l lo w .
2.
3.
4.
5.
S
S
B
G
1.
2.
S h if t le v e r s e a l s tiff.
S h ift lin k a g e o u t o f a d ju s t m e n t o r b in d
h ift lin k a g e d a m a g e d .
y n c h r o n iz e rs w o rn o r d a m a g e d .
e a r in g s w o rn o r d a m a g e d .
e a rs w o rn o r d a m a g e d .
5.
6.
in g .
P ilo t b e a r in g
D ir t b e tw e n
T ra n s m is s io n
M a in d r iv e g
7.
aged.
T r a n s m is s io n n o t a lig n e d .
3.
4.
lo o s e o r d a m a g e d .
th e c lu tc h h o u s in g
and
lo o s e .
e a r r e ta in e r lo o s e o r d a m
c t le v e l.
3.
R e p la c e . R e fe r to C L U T C H
4.
C le a n th e m a tin g s u r fa c e s .
5.
T ig h te n .
6.
T ig h te n o r r e p la c e .
7.
A lig n .
(S E C . 7 C ).
ON VEHICLE SE R V IC E
|-n-| Install o r Connect (Figure 1)
T o o l R e q u ire d :
J -2 1 4 2 6 , R e a r E x te n s io n S e a l In s ta lle r.
1. L o c k i n g c o m p o u n d o n t h e o u t s i d e o f a n e w s e a l ( 1 0 5 ) .
2 . N e w s e a l (1 0 5 ), j s e J -2 1 4 2 6 (fig u re 3 ).
F ill b e t w e e n t h e s e a l lip s w it h c h a s s i s g r e a s e .
3 . P r o p e l l e r s h a f t . R e f e r t o PROPELLER SHAFT (SEC.
100 102
101/103
4 A ).
4 . N e w t r a n s m is s io n o il. R e f e r t o D r a i n a n d F il l in t h is
s e c tio n .
105
REAR RETAINER SEAL (4 SPEED)
++
R a is e t h e v e h ic le .
1. T r a n s m i s s i o n o i l .
2 . P r o p e lle r s h a ft. R e f e r to P R O P E L L E R
100.
101.
102.
103.
104.
105.
106.
107.
S p r in g W
S c re w
F ille r P lu
D r a in R u
T r a n s m is
S eal
R e ta in e r
S c re w
ash er
g
g
s io n
108.
109.
110.
111.
112.
113.
114.
G
S
S
A
C
S
P
ear
eal
le e v e
d a p te r
a b le
eal
lu g
5. N u t (-*2 3 ) a n d th e fla n g e (1 2 2 ).
6. T r a n s m is s io n m o u n t.
S u p p o r t t h e tr a n s m is s io n w ith ja c k .
7. S c r e w s ( 1 2 5 ) a n d t h e r e t a i n e r
th e c a s e .
9 . S e a l ( 105).
Figure 1Transmission and Components (3 Speed/

4 Speed D.D. Typical)
install or Connect (Figure 2)

j- 2 2 8 3 4 . R e a r R e ta in e r S e a i in s ta lle r
DRAIN AND FILL
L o c k in g c o m p o u n d o n th e o u ts id e o f a n e w s e a l
\ e w s e a i (1 0 5 ), u s e J - 2 2 8 3 4 - 2 (fig u r e 4 ).
-- Remove or Disconnect (Figures 1 and 2)

1 . T h e f ille r p lu g
2 . T h e d ra in s lu g H G 3 ).
3 . T r a n s m is s io n o il.
* C a t c h t h e o i l tin a o a n .
install or Connect (Figures
and 2)
1 . T h e d r a in p lu g ( 1 0 3 ).
2 . M e w t r a n s m is s io n o il.
F ill to t h e e v e i o f t h e f i ll e r p lu g
L u b r i c a t i o n ' in t h is s e c t i o n .
3 . T h e fille r o fu g
n o ie . R e f e r to
1102).
S e a l (1 0 5 ).
U s e J - 2 2 8 3 4 - 1 if a p a r k i n g b r a k e is u s e d .
F ill b e t w e e n t h e s e a l lip s w it h c h a s s i s g r e a s e .
SPEEDOMETER DRIVEN
GEAR
REAR EXTENSION SEAL (3 SPEED AND

4 SPEED O.D.)
4A).
section.
Lower the vehicle.
]+) Remove or Disconnect (Figures 1 and 2))
SH A FT
(S E C .
(105).
3. N e w g a s k e t (1 2 0 ).
4. R e t a i n e r 1 2 1 ) a n d t h e s c r e w s ( 1 2 5 ) .
5. T r a n s m is s io n m o u n t.
R e m o v e th e ja c k .
5. F l a n g e 1 2 2 ) a n d t h e n u t ( 1 2 3 ) .
7. N e w s e a i ( 1 1 3 ) a n d t h e s p e e d o m e t e r c a b l e (112).
3. P a r k i n g b r a k e i f j s e d . R e f e r t o B R A K E S ( S E C . 5).
9. P r o p e l l e r s h a f t . R e f e r t o P R O P E L L E R S H A F T ( S E C .
4 A ).
^0. N l e w t r a n s m i s s i o n o il . R e f e r t o D r a i n a n d F i l l i n t h i s
REAR OIL SEAL
R a is e t h e ^ e h ic ie .
T r a n s m i s s i o n o il.
P r o p e lle r s h a ft. R e fe r to p R O P E L L R
(121).
3. G a s k e t (1 2 0 ).
S c r a p e a ll g a s k e t m a t e r ia l fr o m t h e r e t a in e r a n d
8 -0 8 7 4 4
S H A F T (S E C .
4 A ).
3 . P a r k i n g b r a k e if u s e d . R e f e r t o B R A K E S ( S E C . 5 ) .
4 . S p e e d o m e t e r c a b l e ( 1 1 2 ) a n d t h e s e a l (113).
1.
2.
3.
4.
R
S
A
R
S
a is e th e /e h ic le .
p e e d o m e te r c a b le (1 1 2 ) a n d th e s e a i (1 1 3 ).
d a p t e r (1 1 1 ) if u s e d .
e ta in e r (1 0 6 ) a n d th e s c r e w (1 0 7 )
used.
le e v e 1 1 0 ).
,124
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
120.
121.
122.
123.
124.
125.
107 /
106
Spring W asher
Screw
F ille r Plug
Drain Plug
Transm ission
Seal
R etainer
Screw
Speedom eter Driver Gear
Seal
Sleeve
A dapter
S peedom eter Cable
Seal
Plug
Harness
Gasket
Rear Bearing R etainer
U-joint Flange
Nut
Screw
Screw
B-08639
Figure 2Transmission and Components (4 Speed)
5 . S e a l (1 0 9 ).
6. G e a r (1 0 8 ).
|-<-| Install or Connect (Figures 1 and 2)

P u t a t h in c o a t o f t r a n s m is s io n o il o n t h e g e a r a n d
s e a l.
1. G e a r (1 0 8 ).
2 . N e w s e a l (1 0 9 ) o n to th e s le e v e (1 1 0 ).
3 . S le e v e (1 1 0 ).
4 . R e t a in e r ( 1 0 6 ) a n d t h e s c r e w ( 1 0 7 ) if u s e d .
Figure 3Rear Extension Seal Installation

(3 Speed/4 Speed O.D.)
137
133
147
146
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
S h ift Rod, 1st/Rev.

Spacer
Spring
Retainer
S h ift Rod, 2nd/3rd
C ross Lever
S h ift Lever
Retainer
S h ift Lever
Screw
140.
141.
142.
143.
144.
W asher
Swivel
Spring
W asher
Insu lato r
140
145.
146.
147.
148.
Bracket
Nut
Spring W asher
Screw
B-08644
Figure 5Column Shift Linkage

5 . A d a p t e r ( 1 1 1 ) if u s e d .
6 . N e w s e a l (1 1 3 ) a n d th e s p e e d o m e te r c a b le (1 1 2 ).
1 1. C r o s s le v e r (1 3 5 ).
SHIFT LINKAGE
P u t a th in c o a t o f g r e a s e o n t h e in s u la to r .
1. C ro s s le v e r (1 3 5 ).
STEERING COLUMN LINKAGE
1. R e ta in e r (1 3 3 ).
2 . S h if t ro d fr o m t h e c o lu m n .
3 . S p rin g (1 3 2 ) a n d th e s p a c e r (1 3 1 ).
4 . S c re w (1 3 9 ) a n d th e w a s h e r (1 4 0 ).
130.
134.
149.
150.
151.
A.

S h ift Rod, 2nd/3rd
Lever
Lever
Relay Lever
Gage Pin
150
5 . S h if t r o d a n d t h e s w iv e l (1 4 1 ) fr o m t h e s h ift le v e r ( 1 3 8 ) .
6 . S w iv e l (1 4 1 ).
7. R e ta in e r (1 3 7 ).
8 . N u ts (1 4 6 ), th e s p rin g w a s h e r s (1 4 7 ) a n d th e s c r e w s
(1 4 8 ).
9 . B ra c k e t (1 4 5 ).
1 0 . In s u la to r ( 1 4 4 ), th e w a s h e r (1 4 3 ) a n d th e s p r in g (1 4 2 ).
B-08483
Figure 6Column Linkage Adjustment
155.
156.
157.
158.
159.
160.
161.
162.
163.
S h ift Rod, 1st/2nd

S h ift Rod, 3rd/OD
S h ift Rod, Rev.
S h ift C ontrol Lever
S h ift C ontrol
R etainer
W asher
C ontrol Lever
164.
165.
166.
167.
168.
169.
170.
A.
B.
S h ift Rod, 3rd/4th

Nut
Swivel
Nut
S h ift Lever
W asher
Retainer
Gage Pin
Gage Pin Hole
B-08490
Figure 7Floor Shift Linkage (3 Speed/4 Speed O.D.)

T h e s p r in g
( 1 4 2 ) , t h e w a s h e r ( 1 4 3 ) a n d t h e in s u la to r
3. W a s h e r (1 6 9 ).
(1 4 4 ).
B ra c k e t (1 4 5 ).
S c r e w s (1 4 8 ), n e w s p r in g w a s h e r s (1 4 7 ) a n d th e n u ts
4 . N e w r e ta in e r (1 7 0 ).
(1 4 6 ).
N e w r e ta in e r (1 3 7 ).
S w iv e i (1 4 1 ) o n to t h e s h ift ro d .
S h if t r o d a n d t h e s w iv e l (1 4 1 ) to t h e s h ift le v e r ( 1 3 8 ) .
W a s h e r ( 1 4 0 ) a n d t h e s c r e w ( 1 3 9 ) lo o s e ly .
7. N e w r e ta in e r (1 6 0 ).
5 . S h ift ro d to t h e c o n tr o l le v e r (1 6 2 ).
6 . W a s h e r (1 6 1 ).
SHIFT LINKAGE
ADJUSTMENT
Im portant
9. S p a c
10. S h i f t
11 . N e w
T h e w a s h e r m u s t s t a n d o ff t h e le v e r a s s h o w n .
e r (1 3 1 ) a n d th e s p r in g (1 3 2 ).
ro d to t h e c o lu m n .
r e ta in e r (1 3 3 ).
COLUMN SHIFT LINKAGE

A djust (Figures 5 and 6)
T h e fir s t a n d r e v e r s e s h ift r o d ( 1 3 0 ) m u s t b e a d ju s t e d
b e f o r e t h e s e c o n d a n d th ir d s h ift r o d ( 1 3 4 ) .
A d ju s t t h e s h ift lin k a g e .
FLOOR SHIFT LINKAGE
L o o s e n t h e s c r e w ( 1 3 9 ) if n e e d e d .
P u t t h e t r a n s m is s io n l e v e r in p la c e .

1. R e ta in e r (1 6 0 ).
2 . W a s h e r (1 6 1 ).
F o r s h ift r o d ( 1 3 0 ) , m o v e t h e s h ift le v e r ( 1 2 8 ) to
th e fro n t d e te n t (R e v e rs e ).
F o r s h ift r o d ( 1 3 4 ) , m o v e t h e s h ift le v e r to t h e
fro n t d e te n t th e n b a c k o n e , (n e u tr a l).
3 . S h ift ro d fr o m t h e c o n tr o l le v e r (1 6 2 ).
4 . R e ta in e r (1 7 0 ).
3 . P u t t h e c o lu m n l e v e r in p la c e .
5. W a s h e r (1 6 9 ).
6 . S h if t ro d fr o m t h e s h ift le v e r (1 6 8 ).
7 . N u ts (1 6 5 a n d 1 6 7 ) a n d th e s w iv e l (1 6 6 ).
1. Nuts (165 and 167) and the swivel (166).
D o n o t tig h te n .
F o r s h ift r o d ( 1 3 0 ) , m o v e t h e c o lu m n
le v e r in to
R e v e r s e a n d lo c k t h e s te e r in g c o lu m n .
2 . S h if t r o d to t h e s h ift le v e r (1 6 8 ).
4.
F o r s h ift r o d ( 1 3 4 ) , m o v e t h e c o lu m n le v e r in to
N e u t r a l a n d p u t a 0 . 2 4 9 - 0 . 2 5 0 in . g a g e p in
t h r o u g h th e le v e r s ( 1 4 9 a n d 1 5 0 ) a n d t h e r e la y
le v e r (1 5 1 ) (fig u r e 6 ).
H o ld t h e s h if t r o d ( 1 3 0 o r 1 3 4 ) d o w n t i g h t ly in t h e s w iv e l
(1 4 1 ) a n d tig h te n th e s c r e w (1 3 9 ).
RV
4 Speed O.D.
R-V 3 Speed
G 4 Speed O.D.
A.
B.
158.
159.
175.
176.
178.
179.
180.
Locating Hole
F ittin g D irection
S h ift Control Lever
S h ift Control
Knob
Nut
Boot
Bracket
Spring W asher
181.
182.
183.
184.
185.
186.
187.
N uts
Screw
Screw
F ittin g
Gear Position
Screw
Plate
B -0 8 4 9 7
Figure 8Floor Shift Control (3 Speed/4 Speed O.D.)
SHIFT CONTROL
U n l o c k t h e s t e e r i n g c o lu m n , o r t a k e t h e g a g e p in
o u t.
5 . L u b r ic a t e a ll r o d a n d s w iv e l c o n n e c t io n s . R e f e r
M A I N T E N A N C E A N D L U B R IC A T IO N ( S E C . O B ).
to
FLOOR SHIFT CONTROL
El
FLOOR SHIFT LINKAGE
1. K n o b (1 7 5 ) a n d th e n u t (1 7 6 ).
2 . S c r e w s (1 8 6 ) a n d th e b o o t (1 7 8 ).
A djust (Figure 7)
1 . L o o s e n t h e n u t s ( 1 6 5 a n d 1 6 7 ) if n e e d e d .
2 . M o v e t h e s h ift c o n tr o l le v e r ( 1 5 8 ) in to N e u t r a l .
3 . M o v e t h e s h ift le v e r s ( 1 6 2 ) to t h e f r o n t d e t e n t t h e n b a c k
o n e , (n e u tr a l).
4.
Put a
0 .2 4 9 -0 .2 5 0
P l a t e ( 1 8 7 ) if u s e d .
3 . S h ift c o n tr o l le v e r (1 5 8 ).
S lid e a p ie c e o f s h im
s to c k b e tw e e n
th e
a n d t h e c o n tr o l to r e le a s e t h e le v e r .
4 . S h ift r o d s a t th e c o n tr o l (fig u r e 7 ).
in . g a g e
p in
th ro u g h
th e
c o n tro l
le v e r s (1 5 8 ).
G e a r p o s it io n s w it c h ( 1 8 5 ) if u s e d .
5 . S c r e w s ( 1 8 3 ) a n d t h e fittin g ( 1 8 4 ) .
5 . H o l d t h e s h if t r o d s f o r w a r d t i g h t ly in t h e s w iv e ls ( 1 6 6 )
a n d tig h te n th e n u ts (1 6 5 a n d 1 6 7 ).
6 . S h ift c o n tr o l (1 5 9 ).
7. S c r e w s (1 8 2 ) a n d th e s p rin g w a s h e r s (1 8 0 ).
6 . R e m o v e t h e g a g e p in a n d lu b r i c a t e t h e s h if t c o n t r o l.
R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C .
O B ).
8 . N u t s ( 1 8 1 ) a n d t h e s p r i n g w a s h e r s ( 1 8 0 ) , if u s e d .
9 . B ra c k e t (1 7 9 ).
le v e r
192
175.
176.
190.
191.
192.
193.
194.
195.
A.
B.
Knob
Nut
S h ift Lever
Boot
Cap
Screw
R etainer
Screw
Remove
Install
B-08495
Figure 9Shift Control Lever (4 Speed)

1. B ra c k e t (1 7 9 ).
2.
N e w s p r i n g w a s h e r s ( 1 8 0 ) a n d t h e n u t s ( 1 8 1 ) , if u s e d .
SHIFT CONTROL LEVER (4 SPEED)

3 . N e w s p r in g w a s h e r s (1 8 0 ) a n d th e s c r e w s (1 8 2 ).
1. T r a n s fe r c a s e s h ift le v e r b o o t
4 . S h ift c o n tr o l (1 5 9 ).
2 . S c r e w s ( 1 9 3 ) a n d t h e r e t a in e r ( 1 9 4 ) if u s e d .
5 . F ittin g ( 1 8 4 ) a n d t h e s c r e w s ( 1 8 3 ) .
Im portant
P u sh
th e
cap
(1 9 2 )
c o u n te r -c lo c k w is e (A ).
d ow n
2.
P u s h th e c a p (1 9 2 ) d o w n a n d tu r n c lo c k w is e (B ).
3 . S c r e w s ( 1 9 3 ) if u s e d .
4 . R e t a i n e r ( 1 9 4 ) a n d t h e s c r e w s ( 1 9 3 ) if u s e d .
5 . T r a n s fe r c a s e s h ift le v e r b o o t
W ip e th e le v e r w ith a d a m p rag b e fo re s lid in g it

in to p la c e .
if
used.
SIDE COVER
8. B o o t (178) a n d th e s c re w s (186).
A d ju s t th e s h ift lin k a g e .
tu rn
B o o t (1 9 1 ).
7. S h ift c o n tro l le v e r (158).
10. L u b ric a te th e s h ift c o n tro l a n d th e s h ift lin k a g e . R e fe r

to M A IN T E N A N C E A N D L U B R IC A T IO N (SEC. OB).
an d
T h e lu b ric a tio n fittin g m u s t p o in t in th e d ire c tio n

s h o w n (B).
9. N u t (176) a n d th e k n o b (175).
to
B o o t (1 9 1 ).
1. L e v e r (1 9 0 ).
P la te (187), if u se d .
re fe r
5. L e v e r (1 9 0 ).
T h e s c re w w ith th e lu b ric a tio n fittin g m u s t g o into

th e to p h ole .
G e a r p o s itio n s w itc h (185), if u se d.
used,
3 . S c r e w s ( 1 9 3 ) if u s e d .
4.
T h e s c re w w ith th e la rg e s h o u ld e r is a lo c a tin g
s c re w a n d m u s t b e in s ta lle d in th e re a r-c e n te r
h o le (A).
6. S h ift ro d s a t th e c o n tro l (fig u re 7).
if

2.
H a rn e s s e s (2 0 6 ) a s u s e d .
3 . S h ift r o d s (fig u r e 7 ).
M o v e t h e s h ift le v e r s in to n e u t r a l.
R e fe r
to
168.
200.
201.
202.
203.
204.
S hift Lever
205. Side Cover
S h ift Lever, Rev. 206. Harness
W asher
207. Spring
Nut
208. Detent Ball
S h ift Fork
209. Seal
Gasket
210. W asher
211. Nut
212. Screw
213. Spring W asher
214. Bracket
A. Locating Hole
4 SPEED O.D.
200\
207
202 208
210
B-08543
Figure 10Side Cover (3 Speed/4 Speed O.D.)

4 . N u t ( 2 0 2 ) , t h e w a s h e r a n d t h e r e v e r s e s h ift le v e r ( 2 0 0 ) ,
(4 s p e e d O .D .).
S e a l (2 0 9 ).
5 . S c r e w s (2 1 2 ), s p r in g w a s h e r s (2 1 3 ) a n d th e b r a c k e ts
(2 1 4 ).
6 . S id e c o v e r (2 0 5 ).
L ift t h e r e v e r s e in t e r lo c k le v e r to s e a t t h e c o v e r ,
(4 s p e e d O .D .).
T h e s h if t l e v e r s m u s t b e in n e u t r a l .
4 . B ra c k e ts (2 1 4 ),
s c re w s (2 1 2 ).
N o te th e
r e m o v in g .
7. R e v e rs e
d e te n t
p o s itio n s
o f th e
b a ll ( 2 0 8 ) a n d
th e
s h ift
fo rk s
s p r in g
w h ile
(2 0 7 ),
w a s h e rs
(2 1 3 ) a n d
th e
T h e s c r e w w it h t h e l a r g e s h o u l d e r is a lo c a t in g
s c r e w a n d m u s t b e i n s t a l l e d in t h e r e a r - c e n t e r
h o le (A ).
5 . R e v e r s e s h ift le v e r ( 2 0 0 ) , t h e w a s h e r a n d t h e n u t ( 2 0 2 ) ,
(4 s p e e d O .D .).
8. G a s k e t (2 0 4 ).
(4
s p e e d O .D .).
s p rin g
Im portant
Im portant
new
S c r a p e a ll g a s k e t m a t e r ia l fr o m t h e c o v e r a n d t h e
case.
N e w s e a l (2 0 9 ).
6 . S h ift r o d s ( fig u r e 7 ).
7. H a r n e s s e s (2 0 6 ) a s u s e d .
1. N e w g a s k e t (2 0 4 ).
2. R e v e rs e
d e te n t s p r in g
s p e e d O .D .).
3 . S id e c o v e r (2 0 5 ).
(2 0 7 )
and
th e
b a ll ( 2 0 8 ) ,
(4
8 . N e w t r a n s m is s io n o il. R e f e r to D r a in a n d F ill in t h is
s e c tio n .
Lower the vehicle and adjust the shift linkage.

TRANSMISSION REPLACEMENT
++
1. N e w p lu g s (1 1 4 ) if n e e d e d .
P u t a t h in c o a t o f h ig h t e m p e r a t u r e g r e a s e o n t h e
m a in d r iv e g e a r s p lin e s .
2 . T r a n s m is s io n (1 0 4 ).
J -1 1 2 6 , T r a n s m is s io n G u id e P in (4 s p e e d )
2. S h i f t c o n t r o l a n d r o d s i f u s e d , ( 3 s p e e d / 4 s p e e d O . D . ) .
S h if t le v e r , ( 4 s p e e d ) .
P r o p e lle r s h a ft. R e fe r to P R O P E L L E R S H A F T (S E C .
4 A ).
T r a n s f e r c a s e if u s e d . R e f e r t o T R A N S F E R C A S E
(S E C . 7 D ).
5 . P a r k in g b r a k e a n d c o n t r o ls if u s e d . R e f e r t o B R A K E S
(S E C . 5 ).
6. S p e e d o m e t e r c a b l e ( 1 1 2 ) a n d t h e s e a l ( 1 1 3 ) .
7. W ir in g h a r n e s s e s a s u s e d .
8. E x h a u s t p i p e s . R e f e r t o E X H A U S T ( S E C . 6 F ) .
S u p p o r t t h e t r a n s m is s io n w ith a ja c k .
9 . A n y p a r ts if n e e d e d f o r c le a r a n c e .
10. C r o s s m e m b e r .
11. S c r e w s ( 1 0 1 ) a n d t h e s p r i n g w a s h e r s ( 1 0 0 ) .
R e m o v e t h e t o p tw o fir s t a n d in s t a ll g u id e p in s
J -1 1 2 6 , (4 s p e e d ).
12. T r a n s m i s s i o n ( 1 0 4 ) .
im portant
D o n o t le t t h e tr a n s m is s io n h a n g fr o m t h e c lu tc h .
P u ll t h e tr a n s m is s io n s tr a ig h t b a c k o n t h e c lu tc h
h u b s p lin e s .
S u p p o r t th e c lu tc h r e le a s e b e a r in g .
1 3 . P lu g s (1 1 4 ), if t h e y a r e lo o s e o r d a m a g e d .
N o t e t h e lo c a t io n o f th e p lu g s b e f o r e r e m o v in g .
install o r Connect (Figures 1 and 2)

j-1 1 2 6 , T r a n s m is s io n G u id e P in (4 s p e e d )
S h ift th e tr a n s m is s io n
in s ta llin g .
In s ta ll g u id e p in s J -1 1 2 6 in t h e t o p tw o h o le s (4
s p e e d ).
R e m o v e th e c lu tc h r e le a s e b e a r in g s u p p o rt.
in to
h ig h
gear
b e fo re
Im portant
3.
D o n o t fo r c e t h e tr a n s m is s io n in to th e c lu tc h .
D o n o t le t t h e t r a n s m is s io n h a n g fr o m t h e c lu tc h ,
le a v e t h e ja c k u n d e r t h e tr a n s m is s io n to s u p p o r t
it.
N e w s p rin g w a s h e r s
(100)
a n d th e s c re w s
In s ta ll th e tw o b o tto m s c r e w s
t h e g u id e p in s , ( 4 s p e e d ) .
4 . C ro s s m e m b e r.
(101).
b e fo r e r e m o v in g
R e m o v e th e ja c k .
5 . A n y p a rts th a t w e r e r e m o v e d fo r c le a r a n c e .
6 . E x h a u s t p ip e s . R e f e r to E X H A U S T ( S E C . 6 F ) .
7. W ir in g h a r n e s s e s a s u s e d .
8. N e w s e a l (113) a n d t h e s p e e d o m e t e r c a b l e (112).
9. P a r k i n g b r a k e l e v e r a n d c o n t r o l s i f u s e d . R e f e r t o
B R A K E S (S E C . 5 ).
10. T r a n s f e r c a s e i f u s e d . R e f e r t o T R A N S F E R C A S E
(S E C . 7 D ).
11. P r o p e l l e r s h a f t . R e f e r t o P R O P E L L E R S H A F T ( S E C .
4 A ).
12.
S h if t c o n tr o l a n d r o d s if u s e d ,
S h ift le v e r ( 4 s p e e d ) .
1a
N e w t r a n s m is s io n o il. R e f e r t o D r a i n a n d F ill in t h is
s e c tio n .
(3 s p e e d / 4
s p e e d O .D .).
SPECIFICATIONS
3 SPEED
TRANSMISSION
M 62
R P O
M 64
4 SPEED
4 SPEED O.D.
M 20
M Y 6
M u n c ie
M u n c ie
M u n c ie
N e w P ro c e s s
C a s t Iro n
C a s t Iro n
C a s t Ir o n
C a s t Ir o n /A lu m .
246
246
290
260
1st G ear
2 .8 5
3 .5 0
6 .5 5
3 .0 9
2nd G ear
1 .6 8
1 .8 9
3 .5 8
1 .6 7
3 rd G e a r
1 .0 0
1 .0 0
1 .7 0
1 .0 0
4 th G e a r
1 .0 0
0 .7 3
5 th G e a r
M ake
C a s e M a te r ia l
T o r q u e R a tin g (F t. L b .)
R a tio (:1 )
R e v e rs e
S h a fts C e n te r
D is ta n c e
C lu tc h P la te
D ia m e te r
*3 0 2 m m
2 .9 5
3 .6 2
6 .0 9
3 .0 0
76 m m
76 m m
117 m m
89 m m
(3 .0 in c h )
(3 .0 in c h )
(4 .5 in c h )
(3 .5 in c h )
279 m m
279 m m
279 m m *
302 m m
(1 1 .0 in c h )
(1 1 .0 in c h )
(1 1 .0 in c h )
(1 2 .0 in c h )
(1 2 .0 in c h ) w ith D ie s e l E n g in e
FASTENER TORQUE
Nm
Ft. Lbs.
l u g , D r a i n a n d F i l l ....................................................................................................................
r o s s L e v e r B r a c k e t S c r e w ...............................................................................................
h i f t R o d S w i v e l S c r e w ( C o l u m n S h i f t ) ...................................................................
h if t R o d S w iv e l S c r e w (F lo o r S h ift)
23
25
14
17
18
10
3 S p e e d ...................................................................................................................................
4 S p e e d O . D ..........................................................................................................................
C o n t r o l B r a c k e t S c r e w ...........................................................................................................
25
25
33
18
18
24
C o n tro l M o u n tin g S c r e w
3 S p e e d ...................................................................................................................................
32
23
45
P
C
S
S
4 S p e e d ...................................................................................................................................
C o n t r o l L u b r i c a t i o n S c r e w ..................................................................................................
S i d e C o v e r S c r e w .......................................................................................................................
U - j o i n t F l a n g e N u t .......................................................................................................................
R e a r R e ta in e r S c r e w -4 S p e e d
T o p ...............................................................................................................................................
B o t t o m ......................................................................................................................................
T r a n s m i s s i o n t o C l u t c h H o u s i n g S c r e w ...................................................................
T r a n s m is s io n to M o u n t S c r e w
3 S p e e d / 4 S p e e d ..............................................................................................................
4 S p e e d O . D ..........................................................................................................................
C r o s s m e m b e r t o M o u n t S c r e w .........................................................................................
C r o s s m e m b e r t o F r a m e S c r e w ........................................................................................
20
33
33
15
135
100
27
40
20
45
100
30
74
4
5
5
7
3
4
4
5
7
4
4
5
5
0
0
5
LUBRICATION
C a p a c ity
3 S p e e d ...................................................................................................................................
4 S p e e d / 4 S p e e d O . D ...................................................................................................
1 .5 L
4 .0 L
1 .6 q u ts .
4 .2 q ts .
Type R ecom m ended

3 S p e e d / 4 S p e e d ............................................................................................................................................ A P I G L 5 S A E 8 0 W 9 0
4 S p e e d O . D ..............................................................................................................D e x r o n I I A u t o m a t i c T r a n s m i s s i o n F l u i d
SPECIAL TOOLS
J-22834
J-1126
J-21426
1. Rear Retainer Seal Insta lle r (4 speed)

2. Transm ission G uide Pins (4 speed)
3. Rear Extension Seal Installer
(3 Speed/4Speed O.D.)
B-08476
7C-1
SECTION 7C
CLUTCH
CONTENTS
SUBJECT
PAGE
Description.................................................................................................................................................................... 7C- 2
C lu tc h ...................................................................................................... ................................................................. 7C- 2
Clutch C o n tro ls ........................................................................................................................................................ 7C- 2
Inspection...................................................................................................................................................................... 7C- 2
Linkage...................................................................................................................................................................... 7C- 2
Clutch Pedal.............................................................................................................................................................. 7C- 2
Release Bearing........................................................................................................................................................7C- 2
Hydraulic Clutch........................................................................................................................... ............................ 7C- 2
Diagnosis of C lutch......................................................................................................................................................7C- 3
On-Vehicle S ervice ...................................................................................................................................................... 7C- 4
Hydraulic Clutch P e d a l............................................................................................................................................7C- 4
Mechanical Clutch Pedal..........................................................................................................................................7C- 4
Master Cylinder and Reservoir............................................................................................................................... 7C- 5
Secondary (Slave) Cylinder and Hydraulic L in e ...................................................................................................7C- 6
Clutch Linkage..........................................................................................................................................................7C- 7
Cross L e v e r..............................................................................................................................................................7C- 8
Hydraulic Clutch Bleeding....................................................................................................................................... 7C- 9
Clutch Pedal Free Travel A d ju stm e n t................................................................................................................... 7C- 9
Clutch Assembly and Pilot B ea ring ....................................................................................................................... 7C-11
S pe cifica tio ns.............................................................................................................................................................. 7C-15
Fastener Torque........................................................................................................................................................7C-15
Clutch Pedal Free Travel......................................................................................................................................... 7C-15
L ub rication................................................................................................................................................................ 7C-15
Special T o o ls ................................................................................................................................................................ 7C-16
7C-2 CLUTCH
DESCRIPTION
CLUTCH
CLUTCH CONTROLS
T h e p r in c ip a l c o m p o n e n ts o n a c lu tc h
p la te , p r e s s u r e p la te , d ia p h r a g m - t y p e
r e le a s e b e a r in g .
a r e th e d riv e n
s p rin g a n d a
T h e d r i v e n p la t e is s p li n e d o n t h e t r a n s m is s io n c l u t c h
s h a f t s o t h a t it c a n m o v e b a c k a n d f o r t h w h e n t h e c l u t c h is
d i s e n g a g e d , a n d c a n t u r n t h e s h a f t w h e n t h e c l u t c h is
e n g a g e d . T h e d r iv e n p la t e h a s f r ic tio n p a d s r iv e t e d to
b o t h s i d e s o f it, a n d a f l e x i b l e c e n t e r w i t h s p r i n g s t o
a b s o r b v ib r a tio n .
T h e p r e s s u r e p la t e h a s a m a c h in e d s u r f a c e t h a t fits
a g a in s t th e d r iv e n p la te a n d a d ia p h r a g m -ty p e s p r in g
m o u n te d
in
cover on
th e
p re s s u re
p la te . T h e
s p r in g
h o ld s th e p r e s s u r e p la te a n d d r iv e n p la te to g e t h e r a g a in s t
t h e e n g i n e f ly w h e e l w h e n t h e c lu t c h is e n g a g e d .
T h e r e le a s e b e a r in g is a b a ll- t h r u s t b e a r in g o n a s l e e v e
t h a t p u s h e s in o n t h e c e n t e r o f t h e d i a p h r a g m s p r i n g ,
HYDRAULIC CONTROLS - R-V MODELS

T h e h y d r a u lic c lu tc h h a s a m a s t e r c y lin d e r
s e p a r a t e r e s e r v o ir. T h e c lu tc h p e d a l m o v e s t h e
w ith a
m a s te r
c y lin d e r p u s h ro d a n d a s e c o n d a r y c y lin d e r a t th e c lu tc h
h o u s in g m o v e s th e c lu tc h fo r k a n d th e r e le a s e b e a r in g .
MECHANICAL CONTROLS - G AND P MODELS

G m o d e ls h a v e a p u ll r o d f r o m t h e c lu tc h p e d a l t h a t
m o v e s a c r o s s le v e r . T h e c r o s s le v e r m o v e s t h e c lu tc h fo r k
a n d th e r e le a s e b e a r in g w ith a n a d ju s t a b le r o d .
P m o d e ls h a v e a n u p p e r p u ll ro d fr o m t h e c lu tc h p e d a l
to a b e ll c r a n k le v e r a n d a lo w e r p u ll r o d f r o m t h e b e ll
c r a n k le v e r to a c r o s s le v e r . T h e c r o s s le v e r m o v e s t h e
c lu tc h fo rk a n d th e r e le a s e b e a r in g w ith a n a d ju s ta b le
ro d .
r e le a s in g p r e s s u r e o n t h e p r e s s u r e p la te a n d d r iv e n p la te
to d is e n g a g e th e c lu tc h .
INSPECTION
B e fo r e r e p a ir in g t h e c lu tc h , c h e c k th e t r a n s m is s io n a n d
s h ift lin k a g e , a n d t h e e n g in e m o u n ts to b e s u r e t h e p r o b
le m
LINKAGE
1. C h e c k th e c lu tc h ro d s fo r b e n d in g a n d d a m a g e .
fo r
w o rn
s w iv e ls
and
lo o s e
or
re v e rs e
RELEASE BEARING
d am ag ed
m o u n tin g b ra c k e ts .
3 . C h e c k th e c lu tc h le v e r fo r b e n d in g , w e a r a n d d a m a g e .
B e s u r e t h e r e is s o m e c l e a r a n c e b e t w e e n t h e
c lu t c h le v e r a n d t h e m o u n t in g b r a c k e t s a n d b a ll
s tu d s .
4 . L u b r ic a te t h e c lu tc h lin k a g e .
CLUTCH PEDAL
1. C h e c k t h e b u s h in g s fo r d ir t, w e a r a n d d a m a g e .
2 . C h e c k t h e c lu tc h r e le a s e .
H o l d t h e c l u t c h p e d a l 1 2 . 7 m m (1/2 i n . ) a b o v e t h e
flo o r m a t w ith th e e n g in e r u n n in g a n d th e
p a r k in g b r a k e o n .
M o v e t h e s h ift le v e r fr o m fir s t g e a r to
g e a r a n d b a c k s e v e r a l tim e s .
If t h e s h if t is s m o o t h , t h e c lu t c h is d is e n g a g i n g
fu lly .
A d j u s t t h e c lu t c h l in k a g e a n d r e p e a t , if n e e d e d .
is in t h e c l u t c h .
2. C h eck
1. C h e c k t h e c lu tc h fo r k fo r d ir t, w e a r a n d d a m a g e .
2 . C h e c k th e c lu tc h fo r k fo r p r o p e r in s ta lla tio n a n d
lu b r ic a tio n .
3 . C h e c k th e r e le a s e b e a r in g a n d c le a r a n c e b e tw e e n th e
s p r in g f in g e r s a n d t h e t r a n s m is s io n .
HYDRAULIC CLUTCH
1. C h e c k th e h o s e s fo r c r a c k s a n d w e a r.
2 . C h e c k t h e c y lin d e r s fo r lo o s e m o u n tin g s c r e w s a n d
s ig n s o f le a k a g e .
3 . C h e c k t h e c l u t c h p e d a l t r a v e l , it s h o u l d b e 2 1 0 . 8 m m
(8 .3 in ).
4 . C h e c k th e s e c o n d a r y p u s h ro d tr a v e l a t th e c lu tc h fo rk ,
it s h o u l d b e a t l e a s t 2 5 . 4 m m ( 1 . 0 in ) .
5 . B le e d t h e c o n tr o ls a n d r e p e a t a s n e e d e d .
CLUTCH 7C-3
DIAGNOSIS OF CLUTCH
PROBLEM
Will Not Disengage
(Pedal to the floor
and hard to shift into
reverse).
CORRECTION
POSSIBLE CAUSE
1 . L in k a g e lo o s e o r o u t o f a d ju s tm e n t.
2 . A ir in t h e h y d r a u lic s y s t e m .
3 . M a s t e r o r s e c o n d a r y h y d r a u lic c y lin d e r
s e a ls w o rn .
4 . N o t e n o u g h p e d a l tr a v e l.
1 . T ig h t e n o r a d ju s t.
2.
3.
B le e d a n d c h e c k fo r d a m a g e .
R e p a ir .
4.
A d ju s t t h e
b u m p e r.
lin k a g e
o r tr im
th e
pedal
5.
R e le a s e b e a r in g w o rn o r d a m a g e d .
6.
D r iv e n p la te w o rn o r d a m a g e d .
C lu t c h f o r k o ff t h e b a ll s t u d .
D r iv e n p la te b in d in g .
5.
6.
7.
8.
R e p la c e .
R e p la c e .
In s ta ll c o r r e c tly a n d lu b r ic a te .
R e p a ir o r r e p la c e th e p la te o r c lu tc h
g ear
D r iv e n p la te r u n -o u t m o r e th a n 5 .0 8 m m
9.
R e p la c e .
7.
8.
9.
( 0 .2 0 in .).
Slipping.
Grabbing (Chattering).
1.
2.
L in k a g e o u t o f a d ju s tm e n t.
D r iv e n p la t e fr ic tio n p a d s
3.
4.
5.
soaked.
P r e s s u r e p la te o r fly w h e e l w a r p e d .
D ia p h r a g m s p rin g w e a k .
D r iv e n p la te o v e r h e a te d o r n o t s e a te d .
or
o il
1 . A d ju s t.
2 . R e p la c e . C h e c k fo r le a k s a s n e e d e d .
3.
4.
5.
E n g in e m o u n ts io o s e o r d a m a g e d .
1 . T ig h t e n o r r e p la c e .
D r iv e n p la t e f r ic t io n p a d s o il s o a k e d .
P r e s s u r e p la te o r fly w h e e l w a r p e d .
D r iv e n p la t e fr ic tio n p a d m a t e r ia l b u r n e d
2.
3.
4.
R e p la c e a n d c h e c k fo r le a k s .
R e p la c e a s n e c e s s a ry .
C le a n o ff o r r e p la c e a s n e e d e d .
5.
fly w h e e l.
C lu tc h g e a r w o rn .
5.
R e p a ir t h e tr a n s m is s io n .
1.
2.
D ia p h r a g m s p rin g w e a k .
C lu t c h fo r k io o s e o r o ff t h e b a ll s tu d .
1.
2.
R e p la c e t h e p r e s s u r e p la te .
R e p la c e t h e r e ta in in g s p r in g o r in s ta ll
t h e fo r k c o rr e c tly .
D r iv e n
3.
p la te
o n to
th e
s p r in g s
o re s s u re
w eak
p la te
or
o r o il in t h e
R e p la c e
a n d
c h e c k
fo r
le a k s
as
needed.
d a m p e r.
1.
2.
L in k a g e o u t o f a d ju s tm e n t.
R e le a s e b e a r in g b in d in g .
3.
4.
C lu t c h fo r k o ff t h e b a ll s tu d
s p r in g te n s io n .
L in k a g e 'e t u r n s p r in g s w e a k .
1.
2.
R e le a s e b e a rin g w o rn o r d a m a g e d .
C lu t c h fo r k o ff th e b a ll s tu d .
3.
Pedal Stays On The

Floor When
Disengaged.
Pedal Is Hard To
Push.
Noisy.
n o rm a l
1.
3.
Release Bearing Noisy

With The Clutch
Engaged
R e p la c e a s n e e d e d .
R e p la c e .
A llo w to c o o l a n d m a k e 3 0 - 4 0
s ta rts - D O N O T O V E R H E A T .
2.
3.
4.
o r s m e a re d
Rattling (Transmission
Click).
w o rn
or
lo o s e
1. A d ju s t.
2 . C l e a n , o r r e p l a c e if d a m a g e d , a n d
b r ic a te .
3 . In s ta ll, a n d lu b r ic a te .
lu
4.
R e p la c e .
P ilo t b e a r in g lo o s e
1.
2.
3.
R e p la c e .
In s ta ll c o r r e c tly a n d lu b r ic a te .
R e p la c e . R e fe r to E N G IN E (S E C . 6 A ).
1.
2.
3.
L in k a g e o r r e le a s e b e a r in g b in d in g .
D ia p h r a g m s p r in g w e a k .
R e tu r n s p r in g s b e in g o v e r tr a v e le d .
1.
F r e e u p (o r r e p la c e ) a n d lu b r ic a te .
2.
3.
R e p la c e t h e p r e s s u r e p la te .
A d ju s t t h e lin k a g e o r r e p la c e t h e p e d a l
b u m p e r if w o r n .
1.
2.
3.
4.
L in k a g e b in d in g .
H y d r a u lic in e b lo c k e d o r c r im p e d .
M a s t e r o r s e c o n d a r y c y lin d e r s b in d in g .
D r iv e n p la te w o rn .
1 . F r e e u p (o r r e p la c e ) a n d lu b r ic a te .
2 . C le a n o u t o r r e p la c e .
3 . R e p a ir o r r e p la c e a s n e e d e d .
4 . R e p la c e .
7C-4 CLUTCH
ON-VEHICLE SERVICE
1++I Install or Connect (Figure 1)
1. N e w b u m p e r ( 1 1 1 ) i f n e e d e d .
2. N e w s p a c e r ( 1 1 0 ) a n d n e w b u s h i n g s ( 1 0 4 ) .
C o a t w ith g r e a s e b e fo r e in s ta llin g .
3 . S p rin g (1 0 3 ), th e p e d a l (1 0 9 ) a n d th e s tu d (1 0 1 ).
R e m o v e t h e lo n g s c r e w o r r o d w h ile in s ta llin g t h e
s tu d .
Im portant
T h e s tu d
show n.
m ust be
in s ta lle d
in
th e
d ir e c tio n
4 . B r a c e s (1 0 2 a n d 1 1 2 ).
5 . N u ts (1 0 0 ).
6 . N e w w a v e w a s h e r (1 0 8 ) a n d th e p u s h ro d (1 0 7 ).
7.
8.
9.
10.
T h e w a s h e r m u s t s ta n d o ff th e p e d a l a s s h o w n .
W a s h e r (1 0 6 ) a n d th e r e ta in e r (1 0 5 ).
N e u tr a l s ta r t s w itc h .
T h e lo w e r le f t s id e a ir c o n d i t io n i n g d u c t , if u s e d .
T h e lo w e r s t e e r in g c o lu m n c o v e r s .
1 1 . N e g a t iv e b a t t e r y c a b le .
L u b r ic a te th e c lu tc h p e d a l. R e fe r to M A IN T E N A N C E
A N D L U B R IC A T IO N (S E C . 0 B ).
MECHANICAL CLUTCH PEDAL

100.
101.
102.
103.
104.
105.
106.
Nut
Stud
Outboard Brace
Spring
B ushing
R etainer
W asher
107.
108.
109.
110.
111.
112.
Push Rod
Wave W asher
Pedal
Spacer
Bum per
Inboard Brace

1. N e g a t i v e b a t t e r y c a b l e .
2. C o t t e r p i n ( 1 3 2 ) a n d t h e w a s h e r ( 1 3 1 ) .
3.
4. N e u t r a l s t a r t s w i t c h ( 1 2 5 ) .
N o t e t h e d ir e c t io n t h e s w it c h is m o u n t e d in .
5. N u t ( 1 2 0 ) a n d t h e s p r i n g w a s h e r ( 1 2 1 ) .
6. S c r e w ( 1 3 3 ) a n d t h e w a s h e r ( 1 3 6 ) .
B-08845
Figure 1Hydraulic Clutch Pedal Components
HYDRAULIC CLUTCH PEDAL
A
P
S
10. P
N o t e t h e d ir e c t io n t h e s c r e w is m o u n t e d in .
R e m o v e t h e w a s h e r ( 1 3 4 ) if u s e d .
rm (1 3 5 ) a n d th e w a v e w a s h e r (1 2 2 ).
e d a i ro d (1 2 8 ) a n d th e b u s h in g (1 2 9 ).
p r in g (1 2 7 ).
P u s h t h e p e d a l d o w n , m o v e it t o t h e s i d e a n d le t
it u p t o r e l e a s e t h e s p r i n g .
e d a l (1 2 6 ).

1. N e g a t iv e b a tte r y c a b le .
2 . T h e lo w e r s t e e r in g c o lu m n c o v e r s .
3 . T h e lo w e r le f t s i d e a ir c o n d it io n in g d u c t if u s e d .
4 . N e u tr a l s ta r t s w itc h .
5 . R e ta in e r (1 0 5 ) a n d th e w a s h e r (1 0 6 ).
6 . P u s h ro d (1 0 7 ) a n d th e w a v e w a s h e r (1 0 8 ).
7. N u ts (1 0 0 ).
8 . B r a c e s (1 0 2 a n d 1 1 2 ).
9 . S tu d (1 0 1 ), th e p e d a l (1 0 9 ) a n d th e s p r in g (1 0 3 ).
S lid e a lo n g s c r e w o r r o d in to t h e b r a c k e t w h ile
r e m o v in g t h e s tu d .
1 0 . B u s h in g s (1 0 4 ) a n d th e s p a c e r (1 1 0 ).
1 1 . B u m p e r ( 1 1 1 ) if it is w o r n o r d a m a g e d .
S lid e a lo n g s c r e w o r ro d th r o u g h th e b r a c k e t
w h ile r e m o v in g t h e p e d a l to k e e p t h e b r a k e p e d a l
in p la c e .
11. B u s h i n g s ( 1 2 3 ) .
12. B u m p e r ( 1 2 4 ) i f i t i s w o r n o r d a m a g e d .
&5J* Clean (Figure 2)

M e t a l p a r ts w ith s o lv e n t. W ip e d ry .
P la s tic a n d r u b b e r p a r ts w ith a d r y r a g .
Inspect (Figure 2)
P e d a l (1 2 6 ) fo r w e a r a n d b e n d in g .
B u s h in g s (1 2 3 a n d 1 2 9 ) fo r c r a c k s a n d w e a r .

1 . N e w b u m p e r ( 1 2 4 ) if n e e d e d .
2 . B u s h in g s (1 2 3 ).
C o a t t h e b u s h in g s w it h p e t r o le u m je lly .
CLUTCH 7C-5
131
130
128
126
120.
121.
122.
123.
124.
125.
126.
127.
128.
Nut
Spring W asher
Wave W asher
Bushing
Bum per
Neutral Start S w itch
Pedal
Spring
Pedal Rod
129.
130.
131.
132.
133.
134.
135.
136.
Bushing
Wave W asher
W asher
C otter Pin
Screw
W asher
Arm
W asher
B-08846
Figure 2Mechanical Clutch Pedal Components
MASTER CYLINDER
AND RESERVOIR
3. P e d a l (1 2 6 ).
S lid e th e s c r e w
o r ro d
o u t w h ile
in s ta llin g
th e
p e d a l.
4 . S p r in g (1 2 7 ).
H o ld th e p e d a l u p , n e x t to th e p e d a l s to p to h o o k
t h e s p r in g .
2 . T h e lo w e r s te e r in g c o lu m n c o v e r s .
P u s h t h e p e d a l d o w n , s l i d e i t t o t h e s i d e a n d l e t it
u p a g a in s t t h e p e d a l s to p .
3 . T h e l o w e r l e f t s i d e a i r c o n d i t i o n i n g d u c t , if u s e d .
4 . R e ta in e r (1 0 5 ) a n d th e w a s h e r (1 0 6 ).
5 . B u s h in g (1 2 9 ) a n d th e p e d a l ro d (1 2 8 ).
5. P u s h ro d (1 0 7 ) a n d th e w a v e w a s h e r (1 0 8 ).
6 . N e w w a v e w a s h e r (1 2 2 ) a n d th e a rm (1 3 5 ).
6 . R e s e r v o ir h o s e (1 4 5 ).
7. W a s h e r (1 3 6 ) a n d th e s c re w (1 3 3 ).
7. S e c o n d a r y c y lin d e r h y d r a u lic
m a s te r c y lin d e r (1 4 4 ).
lin e
(1 4 2 )
I n s t a l l t h e w a s h e r ( 1 3 4 ) if u s e d .
8 . N u ts (1 4 3 ) a n d t h e m a s t e r c y lin d e r (1 4 4 ).
I n s t a l l t h e s c r e w in t h e d i r e c t i o n it w a s r e m o v e d
fro m .
9 . G a s k e t (1 4 1 ).
8 . N e w s p r in g w a s h e r (1 2 1 ) a n d th e n u t (1 2 0 ).
fro m
th e
th e
m a s te r
10 S c r e w s ( 1 4 6 ) a n d t h e r e s e r v o i r ( 1 4 0 ) .
9 . N e u tr a l s ta r t s w itc h (1 2 5 ).
S c r a p e a ll g a s k e t m a t e r ia l
c y lin d e r a n d t h e c o w l.
fro m
I n s t a l l t h e s w i t c h in t h e p o s i t i o n it w a s r e m o v e d
fro m .
1. R e m o v e th e a d a p te r (2 2 1 ) a n d th e s e a l (2 2 0 ).
10 . N e w w a v e w a s h e r (1 3 0 ).
2.
1 1 . W a s h e r ( 1 3 1 ) a n d a n e w c o t t e r p in ( 1 3 2 ) .
P u ll t h e d u s t c o v e r ( 2 2 8 ) b a c k a n d r e m o v e t h e s n a p
r in g ( 2 2 7 ) .
3 . S h a k e t h e p u s h ro d (1 0 7 ) a n d t h e p lu n g e r ( 2 2 4 ) o u t.
1 2 . N e g a t iv e b a tte r y c a b le .
A d ju s t th e c lu tc h lin k a g e .
A d j u s t m e n t in t h is s e c t i o n .
R e fe r
to
F re e
T ra v e l
L u b r ic a te t h e c lu tc h p e d a l. R e f e r to M A IN T E N A N C E
4 . R e m o v e t h e s e a l ( 2 2 6 ) . R e m o v e th e s p r in g ( 2 3 0 ) , th e
s u p p o r t ( 2 2 2 ) , t h e s e a l ( 2 2 5 ) a n d t h e s h im ( 2 2 3 ) .
jj ] Clean (Figure 4)
All parts with clean brake fluid.
7C-6 CLUTCH
105
105.
106.
107.
108.
140.
141.
142.
144
143.
144.
145.
146.
143
R etainer
W asher
Push Rod
Wave W asher
Reservoir
Gasket
H ydraulic Line,
Secondary C ylinder
Nut
M aster C ylinder
Reservoir Hose
Screw
B-08847
Figure 3Master Cylinder and Reservoir
Inspect (Figure 4)
The
c y lin d e r
b o re
and
th e
p lu n g e r
fo r
s c ra tc h e s ,
r id g e s , a n d p it t in g .
Assemble (Figure 4)
L u b r ic a t e a ll s e a ls w ith c le a n b r a k e flu id .
In s ta ll t h e s h im ( 2 2 3 ) a n d a n e w s e a l ( 2 2 5 ) w ith t h e fla t
a g a in s t t h e s h im ( 2 2 3 ) . In s ta ll t h e s u p p o r t ( 2 2 2 ) a n d
th e s p r in g (2 3 0 ).
B le e d t h e c lu tc h
R e fe r
to
S p e c ific a tio n s
s y s te m . R e fe r to
in
th is
H y d r a u lic C lu tc h
SECONDARY (SLAVE) CYLINDER

AND HYDRAULIC LINE
++
In s ta ll a n e w s e a l ( 2 2 6 ) .
C o a t t h e c y lin d e r b o r e w ith c le a n b r a k e flu id a n d s lid e

t h e p lu n g e r ( 2 2 4 ) a n d t h e p u s h r o d ( 1 0 7 ) in .
2 . H y d r a u lic lin e ( 1 4 2 ) fr o m t h e s e c o n d a r y c y lin d e r ( 1 5 3 ) .
P u s h t h e p u s h r o d ( 1 0 7 ) in a n d i n s t a l l t h e s n a p r in g
(2 2 7 ). C o a t th e in s id e o f th e d u s t c o v e r ( 2 2 8 ) w ith
r e s e r v o ir.
B l e e d i n g in t h is s e c t i o n .
T h e d u s t c o v e r fo r w e a r a n d c r a c k in g .
F ill t h e
s e c tio n .
g r e a s e a n d s l i d e it i n t o p l a c e .
3 . N u ts (1 5 1 ) a n d th e s e c o n d a r y c y lin d e r (1 5 3 ).
4.
H y d r a u lic lin e ( 1 4 2 ) .
H y d r a u lic
(1 4 4 ).
N u t (1 5 0 ) a n d t h e h y d r a u lic lin e (1 4 2 ).
In s ta ll t h e n u t (1 5 0 ) to
c a b le ( B ) in p la c e .
5 . In s ta ll a n e w s e a l ( 2 2 0 ) a n d th e a d a p t e r (2 2 1 ).
1. R e s e r v o i r ( 1 4 0 ) a n d t h e s c r e w s ( 1 4 6 ) .
2. N e w g a s k e t ( 1 4 1 ) .
3. M a s te r c y lin d e r (1 4 4 ) a n d th e n u ts (1 4 3 ).
4 . S e c o n d a r y c y lin d e r h y d r a u lic lin e ( 1 4 2 ) to t h e m a s t e r
c y lin d e r (1 4 4 ).
5 . R e s e r v o ir h o s e (1 4 5 ).
6. N e w w a v e w a s h e r ( 1 0 8 ) a n d t h e p u s h r o d ( 1 0 7 ) .
lin e
(1 4 2 )
fro m
th e
h o ld
m a s te r
th e
c y lin d e r
s p e e d o m e te r
Im portant
C o v e r a ll h y d r a u lic lin e o p e n in g s to k e e p d ir t a n d
m o is t u r e o u t o f t h e c o m p o n e n ts .
7. W a s h e r (1 0 6 ) a n d th e r e ta in e r (1 0 5 ).
1. R e m o v e th e p u s h ro d (2 4 1 ) a n d th e d u s t c o v e r (2 4 0 ).
8. T h e l o w e r l e f t s i d e a i r c o n d i t i o n i n g d u c t , i f u s e d .
2 . R e m o v e th e s n a p
9 . T h e lo w e r s t e e r in g c o lu m n c o v e r s .
10. N e g a t i v e b a t t e r y c a b l e .
r in g
(2 3 8 ) a n d
s h a k e th e
(2 3 9 ) o u t.
3 . R e m o v e th e s p r in g ( 2 4 2 ) a n d th e s e a l (2 3 7 ).
p lu n g e r
CLUTCH 7C-7
R e m o v e th e n u t (1 5 0 ).
H y d r a u lic
lin e
(1 4 2 )
o n to
th e
m a s te r
c y lin d e r
(1 4 4 ).
H y d r a u lic lin e ( 1 4 2 ) a n d t h e n u t (1 5 0 ).
Im portant
T h e h y d r a u lic lin e m u s t b e u p r ig h t , a s s h o w n .
2 . S e c o n d a r y c y lin d e r (1 5 3 ) a n d th e n u ts (1 5 1 ).
3 . H y d r a u lic lin e ( 1 4 2 ) o n to t h e s e c o n d a r y c y lin d e r ( 1 5 3 ) .
L o w e r th e v e h ic le .
4 . N e g a t iv e b a tte r y c a b le .
B le e d t h e c lu tc h s y s te m . R e f e r to
H y d r a u lic C lu t c h
B l e e d i n g in t h is s e c t i o n .
223 225 222
CLUTCH LINKAGE
228 227 229 226

2 . C o t t e r p in s ( 1 3 2 ) , t h e w a s h e r s
(1 3 1 ) a n d
th e
w ave
w a s h e rs (1 3 0 ).
3 . P e d a l ro d (1 2 8 ) a n d th e b u s h in g (1 2 9 ).
N o te t h e d ir e c tio n t h e ro d w a s r e m o v e d fr o m .
4 . S c r e w s (1 7 2 ) a n d th e b o o t (1 7 1 ).
144.
220.
221.
222.
223.
224.
225.
226.
227.
228.
229.
230.
5 . T h e lo w e r p e d a l r o d (1 6 3 ) , (P m o d e ls o n ly ).
C o t t e r p in s ( 1 6 0 ) , t h e w a s h e r s (1 6 1 ) a n d t h e w a v e
M aster C ylind er
Seal
A dapter
Support
Shim
P lunger
Seal
Seal
Snap Ring
Dust Cover
Push Rod
Spring
w a s h e rs (1 6 2 ).
6 . T h e p u ll b a c k s p r in g ( 1 6 6 ) .
R e t a in i n g s p r i n g ( 1 6 4 ) if u s e d .
7 . C o t t e r p in ( 1 6 7 ) , t h e w a s h e r ( 1 6 8 ) a n d t h e w a v e w a s h e r
(1 6 9 ).
T h e n u t ( 1 6 5 ) , if u s e d .
8 . A d ju s tin g ro d (1 7 0 ).
N o t e t h e d ir e c t io n t h e ro d w a s r e m o v e d fr o m .
j j ] Clean (Figures 7 and 8)

B -0 8 8 4 8
Inspect (Figures 7 and 8)
Figure 4Master Cylinder Components
Clean (Figure 6)
I*
A ll m e t a l p a r t s f o r w e a r , d a m a g e a n d b e n d i n g .
A ll n y lo n a n d r u b b e r p a r t s f o r w e a r a n d c r a c k s .
A ll p a r t s w it h c l e a n b r a k e f lu id .
Inspect (Figure 6)
T h e c y lin d e r b o r e a n d t h e p lu n g e r fo r s c r a t c h e s r id g e s
a n d p it t in g .
T h e d u s t c o v e r fo r w e a r a n d c r a c k in g .
A ll m e t a l p a r t s w it h s o lv e n t . W i p e d r y .
A ll n y lo n a n d r u b b e r p a r t s w it h a c l e a n , d r y r a g .
1. A d ju s tin g ro d (1 7 0 ).
In s t a ll t h e r o d in t h e d ir e c t io n it w a s r e m o v e d
fro m .
2 . N e w w a v e w a s h e r (1 6 9 ), th e w a s h e r (1 6 8 ) a n d a n e w
c o t t e r p in ( 1 6 7 ) .
Assemble (Figure 6)
1 . C o a t a n e w s e a l ( 2 3 7 ) w i t h c l e a n b r a k e f l u i d a n d s l i d e it
in to p la c e a n d in s ta ll t h e s p r in g ( 2 4 2 ) .
t h e p lu n g e r ( 2 3 9 ) in .
p l u n g e r ( 2 3 9 ) in a n d
in s ta ll th e s n a p
r in g
(2 3 8 ).
4 . C o a t t h e in s id e o f t h e d u s t c o v e r ( 2 4 0 ) w ith g r e a s e a n d
s l i d e it i n t o p l a c e . I n s t a l l t h e p u s h r o d ( 2 4 1 ) .
U n c o v e r t h e h y d r a u lic lin e o p e n in g s .
1. H y d r a u lic lin e ( 1 4 2 ) .
n u t ( 1 6 5 ) , if u s e d .
4 . T h e lo w e r p e d a l ro d (1 6 3 ) , (P m o d e ls o n ly ).
2 . C o a t t h e c y lin d e r b o r e w ith c le a n b r a k e flu id a n d s lid e

3. P u s h th e
T h e ja m
3 . T h e p u ll b a c k s p r in g ( 1 6 6 ) .
T h e r e t a i n i n g s p r i n g ( 1 6 4 ) , if u s e d .
N e w w a v e w a s h e rs (1 6 2 ), th e w a s h e rs (1 6 1 ) a n d
n e w c o t t e r p in s ( 1 6 0 ) .
5 . T h e b o o t (1 7 1 ) a n d th e s c r e w s (1 7 2 ).
T h e d im p le m u s t f a c e t h e r e a r o f t h e v e h ic le , (P
m o d e ls o n ly ).
6 . T h e b u s h in g (1 2 9 ) a n d th e p e d a l ro d (1 2 8 ).
In s ta ll th e
fro m .
ro d
in t h e d ir e c t io n
it w a s
re m o v e d
7. N e w w a v e w a s h e rs (1 3 0 ), th e w a s h e rs (1 3 1 ) a n d n e w
c o tte r p in s ( 1 3 2 ) .
7C-8 CLUTCH
Figure 5Secondary (Slave) Cylinder and Hydraulic Line

Clean (Figure 9)
N e g a t iv e b a tte r y c a b le .
A d j u s t t h e c l u t c h , if n e e d e d .
A d j u s t m e n t in t h is s e c t i o n .
R e fe r to
F re e
T ra v e l
L u b r ic a te t h e c lu tc h lin k a g e . R e f e r to M A IN T E N A N C E
A N D L U B R IC A T IO N ( S E C . O B ).
CROSS LEVER
2 . S p r in g s a n d t h e a d ju s tin g ro d (1 7 0 ), ( F ig u r e s 7 a n d 8 ).
3 . P e d a l ro d (1 2 8 ) o r th e lo w e r p e d a l ro d (1 6 3 ), (fig u re s 7
a n d 8 ).
4 . S c r e w s (1 8 5 ) a n d th e s p r in g w a s h e r s (1 8 9 ).
N u ts ( 1 9 0 ), (P m o d e ls o n ly ).
5 . B r a c k e t (1 8 6 ) a n d th e c r o s s le v e r (1 9 1 ).
6 . B a ll s t u d ( 1 8 1 ) , t h e n u t ( 1 8 8 ) a n d t h e s t a r w a s h e r ( 1 8 7 )
fro m th e b ra c k e t (1 8 6 ).
7 . E n g i n e s i d e b a ll s t u d ( 1 8 1 ) if it is w o r n o r d a m a g e d .
A ll m e t a l p a r t s w it h s o lv e n t . W i p e d r y .
A ll n y lo n a n d p la s t ic p a r t s w it h a c l e a n , d r y r a g .
I?
Inspect (Figure 9)
A ll m e t a l p a r t s f o r w e a r , d a m a g e a n d b e n d in g .
A ll n y lo n a n d p la s t ic p a r t s f o r w e a r a n d c r a c k s .

E n g i n e s i d e b a ll s t u d ( 1 8 1 ) if n e e d e d .
N e w s t a r w a s h e r ( 1 8 7 ) , t h e n u t ( 1 8 8 ) a n d t h e b a ll s tu d
(1 8 1 ) o n to th e b ra c k e t (1 8 6 ).
C r o s s le v e r (1 9 1 ) a n d th e b r a c k e t (1 8 6 ).
N e w s p r in g w a s h e r s (1 8 9 ) a n d th e s c r e w s (1 8 5 ).
N u ts (1 9 0 ), (P m o d e ls o n ly ).
P e d a l ro d (1 2 8 ) o r th e lo w e r p e d a l ro d (1 6 3 ), (fig u r e s 7
a n d 8 ).
CLUTCH 7C-9
5 . In s ta ll th e
s e c o n d a ry
c y lin d e r
(1 5 3 )
and
r e fill t h e
r e s e r v o ir ( 1 4 0 ) if n e e d e d .
CLUTCH PEDAL FREE

TRAVEL ADJUSTMENT
P MODELS
6JP
\
240
152.
153.
236.
237.
238.

1 . R e m o v e t h e p u ll b a c k s p r in g (1 6 6 ).
2.
237
L o o s e n th e n u t (2 0 1 ) a t t h e s w iv e l (2 0 2 ).
239
238
T a k e th e s w iv e l ( 2 0 2 ) o u t o f th e c r o s s le v e r (1 9 1 ),
(m o d e ls w ith o u t J F 9 ).
3 . M o v e t h e c lu t c h fo r k ( 2 0 0 ) b a c k u n til t h e c lu t c h s p r in g
p r e s s u r e is f e lt , a n d a d ju s t t h e r o d l e n g t h .
Bleeder Screw
Secondary Cylinder
Cap
Seal
Snap Ring
Models without JF9.
H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r .
T u r n t h e n u t (2 0 1 ) u n til t h e s w iv e l ( 2 0 2 ) fits in to
t h e g a g e h o le (A ), t h e n r e m o v e a ll la s h .
239. Plunger
240. Dust Cover

241. Pushrod
242. Spring
In s ta ll th e s w iv e l ( 2 0 2 ) w ith a n e w w a v e w a s h e r
( 1 6 9 ) a n d c o t t e r p in ( 1 6 7 ) .
Models with JF9.

B -0 8 8 5 0
Figure 6Secondary (Slave) Cylinder Components

6 . A d ju s tin g r o d (1 7 0 ) a n d t h e s p r in g s , (fig u r e s 7 a n d 8 ).
A d ju s t th e c lu tc h lin k a g e .
A d ju s t m e n t in t h is s e c t io n .
R e fe r
to
F re e
T ra v e l
L u b r ic a te th e c lu tc h lin k a g e . R e fe r to M A IN T E N A N C E
A N D L U B R IC A T IO N (S E C . O B ).
HYDRAULIC CLUTCH BLEEDING

R-V MODELS
Bleed (Figures 3 and 5)
2 . R e m o v e t h e s e c o n d a r y ( s l a v e ) c y l i n d e r ( 1 5 3 ) a n d t i p it
s o t h e b l e e d e r s c r e w ( 1 5 2 ) is u p .
3 . H o ld th e c lu tc h p e d a l d o w n , o p e n th e b le e d e r s c r e w
(1 5 2 ) to le t a ir a n d flu id e s c a p e , a n d c lo s e t h e b le e d e r
s c r e w (1 5 2 ). L e t th e c lu tc h p e d a l u p .
4.
H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r .
L o o s e n t h e n u t (1 6 5 ) a n d tu r n t h e n u t ( 2 0 3 ) u n til
it is 7 . 3 7 m m ( 0 . 2 9 - i n . ) f r o m t h e r o d s h o u l d e r ( B ) .
T ig h t e n t h e n u t ( 1 6 5 ) a n d tu r n t h e n u t ( 2 0 1 ) to
r e m o v e a ll la s h .
4.
In s ta ll t h e p u ll b a c k s p r in g (1 6 6 ).
5 . C h e c k t h e c l u t c h p e d a l f r e e t r a v e l a n d r e - a d j u s t if
n e e d e d . R e f e r to C lu t c h P e d a l F r e e T r a v e l in t h is
s e c tio n .
6 . L u b r ic a te th e c lu tc h lin k a g e . R e f e r to M A IN T E N A N C E
G MODELS
1 . F ill t h e r e s e r v o i r ( 1 4 0 ) w it h n e w D O T 3 b r a k e f lu id t o t h e
le v e l o f t h e d ia p h r a g m .
NOTICE: Never, under any circumstances, use

fluid which has been bled fromasystemto fill
the reservoir, as it may be aerated, have too
much moisture content and possibly be
contaminated.

1 . R e m o v e t h e p u ll b a c k s p r in g ( 1 6 6 ) .
2 . L o o s e n th e n u t (2 0 3 ).
3 . M o v e t h e c lu tc h fo r k ( 2 0 0 ) b a c k u n til t h e c lu t c h s p r in g
p r e s s u r e is f e lt .
4.
H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r a n d tu r n th e
n u t ( 2 0 1 ) u n t i l i t i s 7 .1 1 m m ( 0 . 2 8 - i n . ) f r o m t h e c r o s s
le v e r (1 9 1 ).
5 . T ig h t e n th e n u t ( 2 0 3 ) a g a in s t th e c r o s s le v e r (1 9 1 ).
6 . In s ta ll t h e p u ll b a c k s p r in g ( 1 6 6 ) .
Important
7 . C h e c k t h e c l u t c h p e d a l f r e e t r a v e l a n d r e - a d j u s t if
n e e d e d . R e f e r t o C lu t c h P e d a l F r e e T r a v e l in t h is
s e c tio n .
C h e c k a n d r e fill t h e r e s e r v o ir a s n e e d e d w h ile
b le e d i n g s o t h a t a i r is n o t d r a w n in t o t h e s y s t e m .
8 . L u b r ic a te th e c lu tc h lin k a g e . R e fe r to M A IN T E N A N C E
R e p e a t s t e p 3 u n t i a ll a ir is o u t o f t h e s y s t e m .
7C-10 CLUTCH
128.
129.
130.
132.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
Pedal Rod
B ushing
Wave W asher
C o tte r Pin
C o tte r Pin
W asher
Wave W asher
Lower Pedal Rod
R etaining Spring (Except JF9)
Nut
Pull Back Spring
C otter Pin
W asher
Wave W asher
A d ju s tin g Rod
171. Boot
172. Screw
A. Dim ple
B-08840
Figure 7Clutch Linkage P Models
CLUTCH 7C-11
CLUTCH ASSEMBLY AND
PILOT BEARING
CAUTION: When servicing clutch parts, do not
create dust by grinding or sanding clutch disc
or by cleaning parts with a dry brush or with
co m p re sse d a ir. (A w a te r dam pened
clothNOT SOAKEDshould be used). The
clutch disc contains asbestos fibers which can
become airborne if dust is created during
servicing. Breathing dust containing asbestos
fibers may cause serious bodily harm.
131

J - 5 8 2 4 - 0 1 C lu tc h A lig n m e n t T o o l
J - 1 4 4 8 P ilo t B e a r in g P u lle r ( G a s E n g in e O n ly )
J - 2 3 9 0 7 P ilo t B e a r in g P u lle r ( 6 .2 L D ie s e l O n ly )
1. T r a n s m is s io n . R e f e r to T R A N S M IS S IO N (S E C . 7 B ).
2 . A d ju s tin g
ro d
(1 7 0 ) o r th e
s e c o n d a r y c y lin d e r (1 5 3 ),
(fig u re s 5 , 7 o r 8 ).
P u l l b a c k s p r i n g ( 1 6 6 ) if u s e d .
R e t a i n i n g s p r i n g ( 1 6 4 ) if u s e d .
3. S c r e w s (2 1 6 ) a n d th e c o v e r (2 1 5 ).
4 . S c r e w s ( 2 0 8 ) a n d th e fly w h e e l h o u s in g (2 0 7 ).
5. B o o t (2 1 0 ), th e
b e a r in g (2 1 2 ).
c lu tc h
fo rk
(2 0 0 )
and
th e
r e le a s e
P r y t h e c lu t c h fo r k ( 2 0 0 ) o ff t h e b a ll s t u d ( 2 0 9 ) .
P r y th e r e ta in e r
(2 1 1 ) o u t o f th e c lu tc h fo r k (2 0 0 )
if it is w o r n o r d a m a g e d .
6 . B a ll s t u d ( 2 0 9 ) .
7. S c r e w s ( 2 0 6 ) a n d th e s p r in g w a s h e r s (2 0 5 ).
Im portant
128.
129.
130.
131.
132.
164.
166.
167.
168.
169.
170.
171.
172.
Pedal Rod
B ushing
Wave W asher
W asher
C otte r Pin
R etaining Spring
Pull Back Spring
C otte r Pin
W asher
Wave W asher
A d ju s tin g Rod
Boot (Two Piece)
Screw
In s ta ll J - 5 8 2 4 - 0 1 c lu tc h a lig n m e n t to o l o r a u s e d
c lu tc h d r iv e g e a r to s u p p o r t th e c lu tc h .
M a r k th e fly w h e e l, c lu tc h c o v e r a n d a p r e s s u r e
p la t e lu g fo r a lig n m e n t w h e n in s ta llin g .
L o o s e n e a c h s c r e w o n e tu r n a t a t im e to a v o id
w a r p in g th e c lu tc h c o v e r.
8 . C o v e r a s s e m b ly (2 1 3 ) a n d t h e d r iv e n p la t e (2 1 4 ).
R e m o v e t h e c lu tc h a lig n m e n t to o l.
9 . P i lo t b e a r i n g ( 2 1 7 ) if it is w o r n o r d a m a g e d .
U s e J -1 4 4 8 o r J - 2 3 9 0 7 a s n e e d e d (fig u r e 1 2 ).

1. R e m o v e th e s c r e w s (2 1 8 ) a n d s tra p s (2 1 9 ).
2.
N o t e t h e lo c a tio n o f t h e r e tr a c tin g s p r in g s .
R e m o v e t h e p r e s s u r e p la te ( 2 2 0 ) .
Clean (Figure 11)
A ll p a r t s w it h a c l e a n , w a t e r d a m p e n e d c lo t h t o r e m o v e
a n y a s b e s to s fib e r s .
C lu t c h fo r k ( 2 0 0 ) , t h e f ly w h e e l h o u s in g ( 2 0 7 ) a n d t h e
b a ll s tu d ( 2 0 9 ) w it h s o lv e n t . W ip e d ry .
B -0 8 8 3 9
Figure 8Clutch Linkage G Models
NOTICE: The release bearing is permanently

packedwithlubricant andshouldnot besoaked
in cleaning solvent as this will dissolve the
lubricant.
7C-12 CLUTCH
180 180 183

1811182
185 187
184/186 / l 88
170.
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
A.
A d ju s tin g Rod
Seat
Ball Stud
Seal
Spring
Retainer
Screw
Bracket
Star W asher
Nut
Spring W asher
Nut
Cross Lever
Pedal Rod (G M odels)
Lower Pedal Rod (P M odels)
185189
B -0 8 8 4 1
Figure 9Cross Lever
]?
Inspect (Figure 11)
1. N e w
A ll p a r t s f o r w e a r a n d d a m a g e .
C o n ta c t s u r f a c e s fo r s c o r in g , a n d fla tn e s s w ith a
s tr a ig h t e d g e . D r iv e n p la t e r u n -o u t m u s t n o t b e m o r e
th a n 5 .0 8 m m (0 .2 0 -in .).
F r ic tio n p a d s fo r s c o r in g , g o u g e s , a n d
C h e c k t o s e e if t h e y a r e o il s o a k e d .
lo o s e
r iv e ts .
A ll s p li n e s f o r n ic k s , b u r r s a n d s lid in g fit.
A ll s p r in g s f o r b e n d i n g a n d b r e a k s .
p ilo t
J -1 5 2 2
or
L u b r i c a t e t h e b e a r i n g w it h a f e w d r o p s o f m a c h i n e o il.
6.2 L Diesel Engine

T h e b e a r in g
lu b ric a tio n .
is
s e a le d
and
does
not
need
any
In s ta ll J - 5 8 2 4 - 0 1 c lu tc h a lig n m e n t to o l o r a u s e d
c lu tc h d r iv e g e a r to s u p p o r t th e c lu tc h .
A lig n th e m a r k s m a d e d u r in g r e m o v a l.
h o u s in g fo r ru n
3 . N e w s p r in g w a s h e r s ( 2 0 5 ) a n d th e s c r e w s (2 0 6 ).
| 2 | Im portant
T ig h t e n e a c h s c r e w o n e t u r n a t a t im e to a v o id
w a r p in g th e c lu tc h c o v e r.
L in e u p t h e m a r k s m a d e d u r in g r e m o v a l.
2 . S tr a p s (2 1 9 ) a n d th e s c r e w s (2 1 8 ).
In s t a ll t h e r e t r a c t in g s p r i n g s in t h e p o s it io n s t h e y
w e re re m o v e d fro m .

J - 5 8 2 4 - 0 1 C lu tc h A lig n m e n t T o o l
J - 1 5 2 2 P ilo t B e a r in g D r iv e r ( G a s E n g in e O n ly )
J - 3 4 1 4 0 P ilo t B e a r in g D r iv e r ( 6 .2 L D ie s e l O n ly )
R e m o v e t h e c lu tc h a lig n m e n t to o l.
Important
1. In s ta ll th e p r e s s u r e p la te (2 2 0 ) .
U se
Important
o u t u s in g a d ia l in d ic a to r . R u n o u t s h o u ld n o t b e m o r e
th a n 0 .3 8 0 m m (0 .0 1 5 -in .).
if n e e d e d .
2 . D r iv e n p la te (2 1 4 ) a n d t h e c o v e r a s s e m b ly (2 1 3 ).
Measure (Figure 11)

T r a n s m i s s i o n p il o t h o l e in t h e c l u t c h
(2 1 7 )
Gas Engine
B o o t fo r te a r s a n d b r ittle n e s s .
b e a r in g
J - 3 4 1 4 0 a s n e e d e d t o d r i v e t h e b e a r i n g in u n t il t h e t o o l
b o tto m s o u t.
NOTICE: Be careful not to use too much

lubricant Excessivelubricant mayget onclutch
fingers and cause slippage or damage may
result to theclutch.
4 . B a ll s t u d ( 2 0 9 ) .
P a c k t h e s e a t w ith h ig h t e m p e r a t u r e g r e a s e .
5 . C o a t t h e r o u n d e d e n d o f t h e b a ll s t u d ( 2 0 9 ) w ith h ig h
te m p e ra tu re g re a s e .
CLUTCH 7C-13
P a c k t h e b a ll s t u d s e a t fr o m t h e lu b r ic a t io n f ittin g
(A ) o n th e fly w h e e l h o u s in g ( 2 0 7 ) (R - V
m o d e ls
o n ly ).
6 . N e w r e t a in e r ( 2 1 1 ) if n e e d e d .
T h e r e ta in e r m u s t b e in s ta lle d s o th e fin g e r s a n d
t a b s fit in to t h e r e le a s e b e a r in g g r o o v e a n d t h e
r e t a in e r w r a p s a r o u n d t h e fla t s id e o f t h e b a ll
s tu d h e a d .
7. R e le a s e b e a r in g
(2 1 2 ), th e c lu tc h fo rk (2 0 0 ) a n d th e
b o o t (2 1 0 ).
P a c k th e in s id e r e c e s s (A ) a n d th e o u ts id e
g r o o v e (B ) o f t h e r e le a s e b e a r in g ( 2 1 2 ) w it h h ig h
t e m p e r a t u r e g r e a s e a s s h o w n , (fig u r e 1 3 ).
8 . F ly w h e e l h o u s in g ( 2 0 7 ) a n d t h e s c r e w s (2 1 6 ).
9 . C o v e r (2 1 5 ) a n d th e s c re w s (2 1 6 ).
1 0 . A d ju s tin g ro d (1 7 0 ) o r t h e s e c o n d a r y c y lin d e r (1 5 3 ) a s
n e e d e d . (F ig u r e s 5 , 7 o r 8 ).
R e t a i n i n g s p r i n g ( 1 6 4 ) if u s e d .
P u ll b a c k s p r i n g ( 1 6 6 ) if u s e d .
1 1 . T r a n s m is s io n . R e fe r to T R A N S M IS S IO N (S E C . 7 B ).
1 2 . A d ju s t t h e c lu tc h lin k a g e a s n e e d e d .
165.
170.
191.
200.
201.
202.
203.
A.
B.
Nut
A d ju s tin g Rod
Cross Lever
C lutch Fork
Nut
Swivel
Nut
Gage Hole
Rod S houlder
B -0 8 8 4 2
Figure 10Clutch Linkage Adjustment
7C-14 CLUTCH
200.
205.
206.
207.
208.
209.
210.
211.
212.
213.
214.
C lutch Fork
Spring W asher
Screw
Flyw heel H ousing
Screw
Ball Stud
Boot
Retainer
Release Bearing
Cover A ssem bly
Driven Plate
Cover
Screw
Pilot Bearing
Screw
Strap
Pressure Plate
L ubrication F ittin g
(CK M odels Only)
B-08833
Figure 11Clutch Assembly and Pilot Bearing
A. Recess
B. Groove
Figure 12Removing the Pilot Bearing
B-08844
Figure 13Release Bearing
CLUTCH 7C-15
SPECIFICATIONS
FASTENER TORQUE
Flywheel Housing to E ngine................................... ..............................................................

Clutch Pedal Stud ..................................................................................... ............................
Master C ylin d e r........................................................................................... ..
Secondary (Slave) Cylinder....................................... ...........................................................
Cross Lever Ball Stud Bracket Side . . . ........ ........................................................................... ............................
Engine Side (6 Models)............................................... ........................ ........................ ....
(P Models).................................................................................... ..
Adjusting Rod Swivel (G M odels)................................................................
(P M o d e ls )....................................... .............................................
N-m
54
39
18
18
Ft. Lbs.
40
29
13
13
27
54
46
43
27
20
40
34
32
20
CLUTCH PEDAL FREE TRAVEL
G M o d e ls.................................................................... ............ ...............................................

P Models (Without JF9).........................................................................................................
P Models (With J F 9 ) .............................................................................................................
mm
34
34
38
in.
1.375
1.375
1.500
LUBRICATION
Hydraulic Clutch C apacity.................
Type recommended
Fill to level of diaphragm.

Brake fluid meeting DOT 3.
7C-16 CLUTCH
SPECIAL TOOLS
7D1-1
SECTION 7D1
205 TRANSFER CASE

CONTENTS
SUBJECT
PAGE
D e s c rip tio n ...................................................................................................................................................................7D1-1

Maintenance and A d ju s tm e n t.................................................................................................................................. 7D1-2
Diagnosis o f the Transfer C a s e ..............................................................................................................................7D1-2
On-Vehicle S e r v ic e ....................................................................................................................................................7D1-3
Transfer Case R e p la c e m e n t................................................................................................................................ 7D1-3
S pe cifica tio ns.............................................................................................................................................................. 7D1 -5
DESCRIPTION
A .
B.
C.
D.
E.
S h if t R a il L in k
P o p p e t N u ts
F r o n t In p u t S h a ft A s s e m b ly
Id le r a n d R e a r O u tp u t S h a ft N u t
F.
G .
H .
F r o n t O u tp u t S h a ft A s s e m b ly
R e a r O u tp u t A s s e m b ly
F ill P lu g
Id le r S h a ft C o v e r
I.
F ro n t O u tp u t S h a ft R e a r B e a rin g
J.
D r a in
P lu g
F -0 0 0 4 4
f e r c a s e m o u n ts b e h in d t h e tr a n s m is s io n
t o r q u e t o b e t r a n s m it t e d in a p r o p o r t io n a l
f r o n t a x l e a n d t h e r e a r a x l e , r e s u l t i n g in
(fig u r e s 1 a n d 2 ).
T h e s h ift c o n tr o l le v e r fo r t h e t r a n s f e r c a s e
m o u n t e d in t h e p a s s e n g e r c o m p a r t m e n t .
F -0 0 0 4 5
Figure 2Rear View
Figure 1Front View

T h e 2 0 5 tra n s
a n d a llo w s d r iv e
s p lit to b o th t h e
fo u r -w h e e l d riv e
R e ta in e r
is f l o o r -
T h e m o d e l 2 0 5 is a t w o - s p e e d u n it , w h ic h o f f e r s t w o w h e e l o r f o u r - w h e e l d i r e c t d r i v e ( 1 ; 1 r a t i o ) , is
a v a i l a b l e in t w o m o d e s : 2 H f o r t w o - w h e e l d r i v e o r 4 H f o r
f o u r - w h e e l d r iv e . G e a r r e d u c t i o n ( 1 .9 6 : 1 r a t io ) is u s e d in
t h e 4 L p o s itio n . T h is u n it u s e s c o n s t a n t m e s h h e lic a l
g e a r s to c o n n e c t th e in p u t s h a ft, id le r g e a r a n d tw o o u tp u t
g e a r s , th u s a llo w in g g e a r s e le c t io n to m a tc h d r iv in g c o n d i
tio n s .
W h e n d r iv in g in a f o u r - w h e e l m o d e ( 4 L o r 4 H I) , t u r n t h e
h u b s o n th e fr o n t w h e e ls to t h e L o c k e d p o s itio n .
7D1-2 205 TRANSFER CASE
MAINTENANCE AND ADJUSTMENT
1.
K n o b
2.
N u t
3.
S c re w
4.
P la te
5.
L ever
6.
R e ta in e r
7.
B o o t
8.
P in
9.
W ash er
10. W a s h e r
1 1 . L in k
12. R od
13. G ro m m e t
1 4 . F ittin g
1 5 . B o lt
F -0 0 0 3 5
Figure 3Shift Control Component View

LUBRICATION INFORMATION
R e fe r to S e c tio n
ty p e s o f lu b ric a n t.
OB
fo r in fo r m a tio n
LINKAGE ADJUSTMENT AND INSPECTION

on
in te r v a ls
and
P e r io d ic a lly in s p e c t th e lin k a g e s y s te m fo r f r e e d o m o f
o p e r a t io n , p r o p e r e n g a g e m e n t , lo o s e a t t a c h in g b o lts ,
fo r e ig n m a te r ia l, e tc . A d ju s t, c le a n a n d tig h te n a s
n e c e s s a r y (fig u r e 3 ).
DIAGNOSIS OF THE TRANSFER CASE

B e fo r e s e r v ic in g a m a lfu n c tio n , c h e c k th e fr o n t h u b s , a x le s , p r o p e lle r s h a fts , w h e e ls a n d tir e s , tr a n s m is s io n o r c lu tc h .
PROBLEM
Excessive Noise
POSSIBLE CAUSE
CORRECTION
1.
2.
3.
L u b r ic a n t le v e l lo w .
W o r n o r d a m a g e d b e a r in g s .
M is a lig n m e n t o f p r o p e lle r s h a fts o r u n i
1.
2.
3.
F ill a s r e q u ir e d .
R e p la c e .
A lig n .
4.
5.
v e r s a l jo in ts .
F la n g e b o lts lo o s e .
L o o s e a d a p t e r b o lts .
4.
5.
R e fe r to S p e c ific a tio n s .
R e fe r to S p e c ific a tio n s .
Shift Lever Difficult

To Move
B in d in g in s id e t h e tr a n s f e r c a s e .
R e p a ir a s r e q u ir e d .
Shifter Lever
Disengages From
Position
1.
2.
3.
G e a rs w o rn o r d a m a g e d .
S h ift r o d b e n t.
M is s in g d e t e n t b a ll o r s p r in g .
1.
2.
3.
Lubricant Leaking
1.
2.
3.
4.
E
L
L
S
1. A d ju s t le v e l.
2 . R e p la c e .
3 . T ig h te n
x c e s s iv e l u b r ic a n t in c a s e .
e a k in g s e a ls o r g a s k e ts .
o o s e b o lts .
c o r e d f l a n g e in s e a l c o n t a c t a r e a .
4.
R e p la c e .
R e p la c e .
R e p la c e .
R e fin is h o r r e p la c e .
205 TRANSFER CASE 7D1-3
ON-VEHICLE SERVICE
B -0 6 9 1 8
Figure 5Strut Rod Support

(Automatic Transmissions)
2. C o n n e c t i n g r o d t o t h e s h i f t r a i l l i n k o r c o n n e c t t h e
s h ift le v e r to t r a n s f e r c a s e a s r e q u ir e d ( f ig u r e 3 ).
Tighten
N u t s to 1 7 N m ( 1 2 ft. lb s .).
F ro n t p r o p s h a ft to
fla n g e o r y o k e .
th e
tra n s fe r c a s e
fro n t o u tp u t
Tighten
TRANSFER CASE REPLACEMENT
++
R a is e a n d s u p p o r t t h e v e h ic le o n a s u ita b le h o is t.
D ra in th e tr a n s fe r c a s e .
S p e e d o m e t e r c a b le .
S k id p la te s a n d c r o s s m e m b e r s (fig u r e 4 ).
S tr u t ro d (a u to m a tic tr a n s m is s io n s ) (fig u r e 5 ).
R e a r p ro p s h a ft fro m th e c a s e .
M a r k p ro p s h a ft fo r a s s e m b ly re fe re n c e .
T i e it u p a n d m o v e it a w a y f r o m t h e w o r k a r e a .
S h if t le v e r r o d f r o m t h e s h if t r a il lin k .
B o lts a tt a c h in g t h e t r a n s f e r c a s e to t h e t r a n s m is s io n
a d a p t e r (fig u r e 6 ).
S u p p o r t th e tr a n s f e r c a s e w ith a s u ita b le
s ta n d .
T ra n s fe r c a s e .
M o v e th e tr a n s fe r c a s e to th e
in p u t s h a ft c le a r s th e a d a p te r.
B o lts to 1 0 2 N m ( 7 5 ft. lb s .).

R e a r p ro p s h a ft to th e tr a n s fe r c a s e r e a r o u tp u t y o k e .
4.
r e a r u n til t h e
Tighten
B o lts to 2 0 N m (1 5 ft. lb s .).

5 . C r o s s m e m b e r s u p p o r t a n d s k id p la te ,
fig u re 4 ).
Tighten
B o lts to 6 3 N m ( 4 6 ft. lb s .).
S tr u t ro d (a u to m a tic tr a n s m is s io n ) (fig u r e 5 ).
T r a n s m is s io n e n d b o lts to 4 7 N m ( 3 5 ft. lb s .).

T r a n s fe r c a s e e n d b o lts to 1 7 5 N m ( 1 2 9 ft.
lb s .).
S p e e d o m e t e r c a b le .
F ill t h e t r a n s f e r c a s e to t h e
lu b r ic a n t. R e f e r to S e c tio n O B .
F ille r p lu g .
p ro p e r
S u p p o r t t h e t r a n s f e r c a s e in a s u it a b l e s t a n d a n d
p o s itio n th e c a s e to th e t r a n s m is s io n a d a p te r .
B o lts a tta c h in g t h e c a s e to t h e a d a p t e r (fig u r e 6 ).
Tighten
B o lts to 6 1 N m ( 4 5 ft. lb s .).
R e m o v e th e s ta n d .
if r e m o v e d
P lu g to 4 4 N m ( 3 2 ft. lb s .).
L o w e r a n d r e m o v e th e v e h ic le fr o m
h o is t.
le v e l
w ith
MANUAL TRANSMISSION
F-00037
Figure 6Transmission Adapters
SPECIFICATIONS
N-m
Ft. Lbs.
23
17
Nut, Shift Lever-To-Shifter Assembly

Nut, Knob Assembly-To-Shift Lever
33
24
Bolt, Shifter Assembly-To-Transfer Case
135
100
Nut, Shift Arms-To-Case
17
13
Screw, Shift Lever Boot Retainer
2.7
Bolt, Adapter-To-Transmission
33
24
Bolt, Adapter-To-Transfer Case
33
24
Drain Plug
44
32
Filler Plug
44
32
Bolts P.T.O. Cover
22
16
Nut, Skid Plate-To-Crossmember
63
46
31
Bolt, Support Strut Rod

Transmission End
47
35
Transfer Case End
175
129
Transfer Case (Front)
75
55
Transfer Case (Rear)
15
11
Propeller Shaft
MODEL NO.
AVAILABILITY
RATIOS: Hi Range
Lo Range
205 (PART TIME)

All K30 Series
1.00 To 1
1.96 To 1
LEVER POSITIONS
4-Lo (All Wheel Underdrive)

N (Neutral)
2-Hi (Rear Wheel Drive)
4-Hi (All Wheel Direct Drive)
LEVER LOCATION
Rear Of Transmission Shift Lever
POWER TAKE-OFF DATA:

Opening and Location
SAE 6-Bolt; Left Side
LUBRICANTS:
Oil Capacity
5.2 Pints*
Type, Grade
Dexron
*To Be Filled W ithin One Inch Of Fill Plug.
II
In. Lbs.
7D2-1
SECTION 7D2
208 TRANSFER CASE

CONTENTS
SUBJECT
PAGE
Description..................................................... ...............................................................................................................7D2-1
Diagnosis of the Transfer C ase..................................................................................................................................7D2-3
On-Vehicle S ervice ...................................................................................................................................................... 7D2-4
Maintenance and A djustm ent..................................................................................................................................7D2-4
Transfer Case Replacement....................................................................................................................................7D2-5
S pe cifica tio ns...............................................................................................................................................................7D2-8
DESCRIPTION
a n n u lu s g e a r , p r o v id e s t h e fo u r -w h e e l d r iv e lo w r a n g e
w h e n e n g a g e d . R e d u c t i o n r a t io n is 2 .6 1 : 1 in t h is r a n g e .
SHIFT CONSOLE AND LEVER CONTROLS

A f lo o r m o u n t e d s h if t le v e r is u s e d t o s e l e c t
o p e r a t in g r a n g e ( f ig u r e 2 ) . T h e s h if t le v e r is lo c a t e d o n
f lo o r p a n tr a n s m is s io n tu n n e l a d ja c e n t to t h e tr a n s m is s
g e a r s h if t le v e r . T h e s h if t p a t t e r n is n o t in a s t r a ig h t lin e
th e
th e
io n
fo r
2 0 8 m o d e ls (fig u r e 3 ).
FOUR-WHEEL DRIVE INDICATOR LAMP

A n i n d ic a t o r l a m p m o u n t e d in t h e i n s t r u m e n t p a n e l ,
a l e r t s t h e d r i v e r w h e n e v e r t h e v e h i c l e is b e in g o p e r a t e d in
f o u r - w h e e l r a n g e . A n in d ic a t o r s w it c h in t h e t r a n s f e r c a s e
c o n tr o ls t h e lig h t ( F ig u r e 2 ).
T h e s w it c h is a b a ll a n d p lu n g e r u n it a c t iv a t e d b y t h e
r a n g e s e le c t o r w h e n f o u r - w h e e l r a n g e is s e le c t e d .
IDENTIFICATION
F o r s e r v ic in g , a n id e n tific a tio n ta g a t t a c h e d to t h e r e a r
h a lf o f t h e t r a n s f e r c a s e p r o v id e s th e t r a n s f e r c a s e m o d e l
A.
B.
C.
D.
n u m b e r , lo w r a n g e r e d u c tio n r a tio a n d a s s e m b ly n u m b e r .
If t h e t a g is r e m o v e d o r b e c o m e s d is l o d g e d d u r i n g s e r v i c e
o p e r a t io n s , r e a t t a c h u s in g a n a d h e s iv e s e a la n t s u c h a s
L o c tite 3 1 2 o r e q u iv a le n t (fig u r e 1 ).
Id e n tifica tio n Tag

Drain Plug
F ill Plug
In d ica to r S w itch
LUBRICATION
B -0 7 6 8 3
Figure 1Indicator Switch, Identification, Tag and

Drain and Fill Plug Location
T h e M o d e l 2 0 8 tra n s fe r c a s e
is a n a lu m in u m
c h a in d r iv e n , fo u r p o s itio n u n it p r o v id in g fo u r -w h e e l
h ig h a n d lo w r a n g e s , a t w o - w h e e l h ig h r a n g e a n d a
t r a l p o s it io n . T h e m o d e l 2 0 8 is a p a r t - t i m e f o u r - w h e e l
u n it . T o r q u e in p u t in f o u r - w h e e l h ig h a n d lo w r a n g e s
s a m e (fig u r e 1 ).
case,
d riv e
neu
d riv e
is t h e
A tw o -p ie c e a lu m in u m c a s e c o n ta in s fr o n t a n d r e a r o u t
p u t s h a fts , tw o d r iv e s p r o c k e ts , a s h ift m e c h a n is m a n d a
p la n e t a r y g e a r a s s e m b ly . T h e d r iv e s p r o c k e ts a r e c o n
n e c te d a n d o p e r a te d b y th e d r iv e c h a in . T h e p la n e ta r y
a s s e m b ly , w h ic h c o n s is ts o f a fo u r p in io n c a r r ie r a n d a n
C h a n g e th e lu b r ic a n t a t th e in te r v a ls s p
M a in te n a n c e S c h e d u le . W h e n a d d in g lu b r ic
th e tr a n s f e r c a s e a f t e r s e r v ic in g , u s e D e x r o n
th e m a in t e n a n c e a n d a d ju s tm e n ts s e c tio n
c h a n g e p r o c e d u r e s a n d fill l e v e l .
e c i f ie d in t h e
a n t o r r e fillin g
II. R e f e r to
fo r lu b ric a n t
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Knob
Rod
G rom m et
Lever
W asher
Pin
Lever
Nut
Plate
Screw
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Bezel
Boot
Seal
Nut
W asher
Bushing
H ousing
Fork
W asher
Spring
\s
\
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
G uide
Lever
Pin
Swivel
Bolt
Nut
W asher
Bolt
Nut
Nut
Figure 2Console and Shift Control Component View
B-08867
B -0 8 8 9 3
Figure 3Shift Lever
DIAGNOSIS OF THE TRANSFER CASE

B e fo r e r e p a ir in g a s u s p e c t e d t r a n s f e r c a s e p r o b le m c h e c k t h e d r iv e lin e c o m p o n e n ts . T h e p r o b le m
fr o n t h u b s , a x le s , p r o p e lle r s h a fts , w h e e ls a n d tir e s , t r a n s m is s io n o r c lu tc h .
PROBLEM
Transfer Case Difficult
To Shift Or Will Not
Shift Into Desired
Range
POSSIBLE CAUSE
1.
2.
CORRECTION
V e h i c l e s p e e d is t o o g r e a t t o p e r m i t s h if t
in g .
1.
If t h e v e h ic le w a s o p e r a t e d f o r e x t e n d e d
p e r io d in t h e 4 H m o d e o n d r y p a v e d s u r
2.
S to p th e v
to n e u tr a l,
m ode and
d ry p a v e d
3.
L u b r ic a te , r e p a ir o r r e p la c e lin k a g e , o r
tig h te n lo o s e c o m p o n e n ts a s n e c e s
s a ry .
4.
D r a i n a n d r e f ill t o t h e e d g e o f t h e fill
h o le w ith D E X R O N
II.
D is a s s e m b le t h e u n it a n d r e p la c e w o r n
o r d a m a g e d c o m p o n e n ts a s n e c e s s a ry .
3.
T ra n s fe r
b in d in g .
4.
In s u ffic ie n t o r in c o r r e c t lu b r ic a n t.
5.
In te r n a l c o m p o n e n ts
dam ag ed.
1.
In s u ffic ie n t o r in c o r r e c t lu b r ic a n t.
case
e x te rn a l
s h ift
lin k a g e
b in d in g ,
w o rn
is
or
S to p t h e v e h ic le a n d s h ift in to t h e d e
s ir e d r a n g e . O r r e d u c e th e s p e e d to 2 -3
m p h (3 -4 k m /h ) b e fo r e a tte m p tin g to
s h ift .
f a c e , d r iv e lin e to r q u e lo a d m a y c a u s e d if
f ic u lt s h iftin g .
Transfer Case Noisy

In All Drive Modes
m a y b e r e la te d to th e
5.
1.
e h ic le , s h ift t h e t r a n s m is s io n
s h ift t h e t r a n s f e r c a s e to 2 H
o p e r a t e t h e v e h ic le in 2 H o n
s u rfa c e s .
D r a i n a n d r e f ill t o t h e e d g e o f t h e fill
h o le w ith D E X R O N
II. C h e c k fo r
l e a k s a n d r e p a i r if n e c e s s a r y . If u n i t is
s till
n o is y
a fte r
d r a in in g
and
r e fillin g ,
d is a s s e m b le a n d in s p e c t to lo c a te th e
s o u r c e o f t h e n o is e .
Noisy In Or Jumps
Out Of Four Wheel
Drive Low Range
1.
T r a n s f e r c a s e is n o t c o m p l e t e l y e n g a g e d
in 4 L p o s it io n .
1.
S to p t h e v e h ic le , s h ift t h e t r a n s f e r c a s e
in to N e u t r a l, t h e n s h ift b a c k in to t h e 4 L
p o s itio n .
2.
S h if t l in k a g e is lo o s e o r b in d in g .
2.
T ig h te n , lu b r ic a te o r r e p a ir lin k a g e a s
n e c e s s a ry .
3.
R an
fo rk
A nn
dam
or
3.
D is a s s e m b le
n e c e s s a ry .
th e
u n it
and
r e p a ir
as
or
4.
D is a s s e m b le
n e c e s s a ry .
th e
u n it
and
r e p a ir
as
4.
g e F o r k c r a c k e d , in s e r ts w o rn ,
is b in d in g o n s h if t r a il.
u lu s g e a r o r lo c k p la t e is w o r n
ag ed.
7D2-4 GENERAL DESCRIPTION
DIAGNOSIS OF THE TRANSFER CASE (CONT.)

CORRECTION
POSSIBLE CAUSE
PROBLEM
Lubricant Leaking
From Output Shaft
Seals Or From Vent
1.
2.
3.
1.
2.
3.
T r a n s fe r c a s e o v e r fille d .
V e n t c lo s e d o r r e s tr ic te d .
O u tp u t s h a ft s e a ls d a m a g e d o r in s ta lle d
in c o r r e c tly .
D r a in to th e c o r r e c t le v e l.
C l e a r o r r e p l a c e t h e v e n t if n e
R e p la c e s e a ls . B e s u r e s e a l
in te r io r o f c a s e w h e n in s ta lle d
s u re fla n g e s e a l s u rfa c e s
c e s s a ry .
lip f a c e s
. A ls o b e
a re n ot
s c o r e d o r n ic k e d . R e m o v e s c o r e s , n ic k s
w ith fin e s a n d p a p e r o r r e p la c e th e
f l a n g e if n e c e s s a r y .
Abnormal Tire Wear
1.
1.
E x te n d e d o p e r a tio n o n d ry h a rd s u r fa c e
( p a v e d ) r o a d s in 4 H
O p e r a t e in 2 H
o n h a rd s u rfa c e (p a v e d )
ro a d s .
ra n g e .
ON-VEHICLE SERVICE
MAINTENANCE AND
ADJUSTMENT
CASE-OIL CHANGE
P o s itio n a d r a in p a n u n d e r t h e t r a n s f e r c a s e .
D r a i n a n d fill p lu g s .
D r a in th e lu b r ic a n t.
I+ H Install or Connect
1 . D r a in p lu g .
Tighten
24 N m (18
P lu g to
R e m o v e th e d r a in p a n .
ft. lb .).
2.
F ill t h e t r a n s f e r c a s e to t h e e d g e
o p e n in g w ith D E X R O N
II.
F ill p lu g .
o f fill p lu g
Tighten
P lu g to 2 4 N m ( 1 8 ft. lb .).
INSPECTION
P e r io d ic a lly in s p e c t t h e lin k a g e s y s te m fo r fr e e d o m o f
o p e r a tio n , p r o p e r e n g a g e m e n t , lo o s e a tta c h in g b o lts a n d
fo r e ig n m a te r ia l.
LINKAGE ADJUSTMENTS
Gage 129 mm (0.200)

Rod
Grom met
Lever
Lever
Nut
Nut
B-08895
Figure 4Linkage Adjustment

4 . H a n g a 1 2 9 m m ( 0 .2 0 0 ) g a g e (F ) w ith a 6 m m
in c h ) r a d iu s o v e r t h e r o d b e h in d t h e s w iv e l.
Adjust (Figures 1 and 4)

1. P u t t h e t r a n s f e r c a s e le v e r in to t h e 4 H
4 ).
F.
21.
22.
23.
26.
27.
49.
d e te n t (F ig u r e
2 . P u s h t h e lo w e r s h if t e r le v e r ( 2 6 ) fo r w a r d in to t h e 4 H
d e te n t.
3 . In s ta ll t h e r o d s w iv e l (2 1 ) in to t h e s h ift le v e r h o ld .
(0 .2 5
5 . R u n t h e r e a r ro d n u t ( 2 7 ) a g a in s t t h e g a g e w ith th e
s h ifte r a g a in s t t h e 4 H d e t e n t .
6. R e m o v e th e g a g e a n d
a g a in s t th e n u t (2 7 ).
7. R u n th e
tig h te n .
fro n t ro d
push
n u t (4 9 )
th e
s w iv e l
a g a in s t th e
re a rw a rd
s w iv e l a n d
R o ta te
th e
tra n s fe r
case
o u tp u t
s h a ft
(tu rn
f la n g e ) u n til t h e o u p u t s h a f t g e a r e n g a g e s t h e
tr a n s fe r c a s e in p u t s h a ft.
M o v e th e tra n s fe r c a s e fo rw a rd
s e a t s a g a in s t t h e tr a n s m is s io n .
u n til t h e
case
NOTICE: Place the transfer case flush against

the transmission. The case can be damaged if
theattachingboltsaretightenedwhenthecase
is cockedor in abind.
3 . A t t a c h in g b o lts .
B o lts to 4 1 N m ( 3 0 ft. lb s .)
4 . S p e e d o m e te r c a b le .
5 . F r o n t a n d r e a r p r o p e lle r s h a fts .
| ^ \ | Tighten
F r o n t f la n g e b o lts to 1 0 0 N m ( 7 5 ft. lb s .).
| 9 | Im portant
L in e u p t h e r e f e r e n c e
r e m o v a l.
6 . S k id p la t e (fig u r e 7 ).
m a rk s
m ade
d u r in g
Tighten
B o lts to 6 3 N m ( 4 6 ft. lb s .).
Figure 5Strut Rod Support-Automatic

Transmission
P l a c e t h e t r a n s f e r c a s e in 4 H d e t e n t .
D r a in th e lu b r ic a n t fr o m th e tr a n s f e r c a s e .
1. C o t t e r p in fr o m t h e s h if t le v e r s w iv e l ( f ig u r e 2 ).
2 . S p e e d o m e te r c a b le .
3 . In d ic a to r s w itc h w ir e .
4 . F r o n t a n d r e a r p r o p e lle r s h a fts .
fla n g e
fo r
a s s e m b ly
5 . P a r k in g b r a k e c a b le g u id e f r o m t h e p iv o t lo c a t e d o n t h e
r ig h t f r a m e r a il.
6 . E n g in e s tru t ro d
(fig u re 5 ).
on
a u to m a tic
tr a n s m is s io n
m o d e ls
7 . T r a n s fe r c a s e -to -tr a n s m is s io n a d a p t e r b o lts (fig u r e 6 ).
S u p p o r t th e tr a n s fe r c a s e w ith a s u ita b le s ta n d .
8 . S k id p la te (fig u r e 7 ).
9. C a s e .
M o v e t h e t r a n s f e r c a s e r e a r w a r d u n t i l it i s f r e e o f
t h e t r a n s m is s io n o u tp u t s h a ft.
1 0 . G a s k e t m a te r ia l.
P l a c e t h e t r a n s f e r c a s e in 4 H d e t e n t .
P l a c e t h e t r a n s f e r c a s e in a s u p p o r t s t a n d .
1. G a s k e t to t h e tr a n s m is s io n (fig u r e 6 ).
2 . O u tp u t s h a ft.
under
T r a n s m is s io n b o lts to 4 7 N m ( 3 5 ft. lb s .).

T r a n s fe r c a s e b o lts to 1 7 5 N m ( 1 2 9 ft. lb s .).
. F ill t h e t r a n s f e r c a s e w it h D E X R O N
II.
10
M a rk th e s h a fts a n d
a lig n m e n t r e fe r e n c e .
fro m
th e
P a r k i n g b r a k e c a b l e if d is c o n n e c t e d .
Remove or Disconnect (Figures 2, 5, 6 and 7)
s ta n d
C o t t e r p in to t h e s h if t le v e r s w iv e l ( f ig u r e s 2 a n d 4 ) .
S tr u t ro d s u p p o r t to th e tr a n s f e r c a s e o n a u to m a tic
tr a n s m is s io n s (fig u r e 5 ).
TRANSFER CASE REPLACEMENT
R e m o v e th e s u p p o rt
tra n s fe r c a s e .
B-08899
Figure 6Transmission Adapters
Figure 7Skid Plate Installation
SPECIFICATIONS
Nm
Ft. Lbs.
N u t, S h ift L e v e r -T o -S h ifte r A s s e m b ly
23
17
N u t, K n o b A s s e m b ly -T o -S h ift L e v e r
33
24
B o lt, S h ifte r A s s e m b ly -T o -T r a n s fe r C a s e
130
96
17
13
S c r e w , S h ift L e v e r B o o t R e t a in e r
2 .7
24*
B o lt, D e t e n t R e t a in e r
31
23
S w itc h , In d ic a to r
149
111
B o lt, A d a p te r -T o -T r a n s m is s io n
33
24
B o lt, A d a p te r -T o -T r a n s m is s io n C a s e
33
24
F ille r P lu g
47
35
N u t, S k id P la te -T o -C r o s s m e m b e r
63
47
47
35
175
129
N u t, S h ift A r m s -T o -C a s e
B o lt, S u p p o r t S tr u t R o d
T ra n s m is s io n E n d
T ra n s fe r C a s e E n d
B o lts , F r o n t P r o p e lle r S h a f t F la n g e
100
74
T ra n s fe r C a s e , F ro n t
75
55
T ra n s fe r C a s e , R e a r
15
11
In c h P o u n d s
Model No.
Ratios:
208 (Part Time)
Hi R ang e
Lo R ang e
Lever Positions
2 .6 1 to 1
4 - L o ( A ll W h e e l U n d e r d r iv e )
2 -H i (R e a r W h e e l D r iv e )
4 - H i ( A ll W h e e l D r iv e )
Lever Location
R e a r o f T ra n s . S h ift L e v e r
Lubricant:
O il C a p a c it y
T ype, G ra d e
* F ill T o T h e E d g e O f T h e P l u g H o l e .
1 0 P in ts *
D E X R O N
II
8A-1
SECTION 8
ELECTRICAL
CONTENTS
SUBJECT
PAGE
Cab E le c tric a l.............................................................................................................................................................. 8 A - 1

Chassis E lectrical........................................................................................................................................................ 8 B - 1
Instrum ent P a n e l........................................................................................................................................................ 8C - 1
SECTION 8A
CAB ELECTRICAL
CONTENTS
SUBJECT
PAGE
Basic E lectrical............................................................................................................................................................ 8 A - 2
C ircuits ..................................................................................................................................................................... 8 A - 2
Wire Size Conversion T a b le ................................................................................................................................ 8 A - 4
C ircuit M alfu nctio n s................................................................................................................................................8 A - 4
C ircuit D ia g n o s is ....................................................................................................................................................8 A - 4
Diagnostic Tools...................................................................................................................................................... 8A - 4
C ircuit Maintenance and R e p a ir..........................................................................................................................8 A - 6
Cab Electrical S y s te m s ........................................................................................... ................................................. 8 A - 9
RV Cab Harness R o u tin g s .....................................................................................................................................8 A - 9
RV Fuse B lo c k ........................................................................................................................................................ 8A -14
G Van Cab Harness R o u tin g s .............................................................................................................................. 8A -15
G Van Fuse B lo ck.................................................................................................... ............................................... 8A -17
Power Door Lock S y s te m .....................................................................................................................................8A - 17
Diagnosis o f Power Door Lock S yste m ................................................................................................................. 8A -23
On-Vehicle S ervice..................................................................................................................................................8A -24
Power W indow S y s te m ......................................................................................................................................... 8A -24
Diagnosis o f Power W indow S yste m ..................................................................................................................... 8A-24
W indshield W iperRV and G M o d e ls ................................................................................................................. .8A-26
D e s c rip tio n ...............................................................................................................................................................8A-26
Diagnosis o f W indshield W ip e r .............................................................................................................................. 8A -28
W indshield W asherRV and G M o d els................................................................................................................. 8A-34
D e s c rip tio n ...............................................................................................................................................................8A-34
W indshield Washer D ia g n o s is ................................................................................................................................ 8A -35
W iper M otor Unit R e p a ir........................................................................................................................................... 8A -36
Replacement o f C o m p o n e n ts .............................................................................................................................. 8A -36
W indshield W iper Delay C ir c u it.............................................................................................................................. 8A -38
D e s c rip tio n .............................................................................................................................................................. 8A -38
Diagnosis o f the Wiper Delay C ir c u it................................................................................................................. 8A -38
W indshield Wiper and WasherP M o d e ls .......................................................................................................... 8A -40
D e s c rip tio n ...............................................................................................................................................................8A-40
D iagnosis...................................................................................................................................................................8A-41
8A-2 CAB ELECTRICAL

C O N T E N T S (C O N T .)
SUBJECT
PAGE
Diagnosis of the W iperO n -V e h icle ..................................................................................................................... 8A-43

Diagnosis of the W iperO ff-V e h icle ..................................................................................................................... 8A-43
Diagnosis of the W asher S y s te m ............................................................................................................................8A-44
On-Vehicle S ervice ................................................................................................................................................. 8A-45
Unit R e p a ir................................................................................................................................................................... 8A-45
Wiper Motor D is a sse m b ly.................................................................................................................................... 8A-45
In s p e c tio n .................................................................................................................................................................8A-45
Wiper Motor A ssem bly........................................................................................................................................... 8A-46
W indshield Washer D isa sse m b ly.......................................................................... ..........................................8A-47
W indshield Washer A ssem bly.............................................................................................................................. 8A-48
Heater System C ircuits ............................................................................................................................................. 8A-48
D e s c rip tio n .............................................................................................................................................................. 8A-48
D iagnosis...................................................................................................................................................................8A-48
On-Vehicle S e rvice ......................................................................................... ........................................................ 8A-48
A ir C onditioning Electrical S y s te m ....................................................................................................................... 8A-48
D e s c rip tio n ...............................................................................................................................................................8A-48
Diagnosis................................................................................................................................................................... 8A-48
On-Vehicle S ervice ..................................................................................................................................................8A-48
Special T o o ls ...............................................................................................................................................................8A-49
BASIC ELECTRICAL
CIRCUITS
A n e le c t r ic a l c ir c u it s t a r t s fr o m a s u p p ly o f e le c tr ic ity ,
c o n d u c t s t h e e le c t r ic it y b a c k to t h e s u p p ly o f e le c tr ic ity .
T h e r e s h o u ld b e a d e v ic e to o p e n a n d c lo s e t h e c ir c u it,
a n d a p r o t e c t iv e d e v ic e to o p e n t h e c ir c u it in c a s e t o o
m u c h c u r r e n t f l o w s in t h e c ir c u it .
E le c tr ic a l c ir c u its c a n b e s e t u p a s s e r ie s c ir c u its o r
p a r a l l e l c ir c u it s . T h e c i r c u i t s in t r u c k s a r e u s u a l l y p a r a l l e l
c irc u its .
SERIES CIRCUITS (Figure 1)

In s e r i e s c i r c u i t s , e a c h e l e c t r i c a l d e v i c e is c o n n e c t e d in
th e c irc u it s o th a t th e c u r r e n t c a n o n ly g o a lo n g o n e p a th
a s it f l o w s f r o m t h e p o w e r s u p p l y , a r o u n d t h e c i r c u i t a n d
b a c k to th e p o w e r s u p p ly .
PARALLEL CIRCUITS (Figure 1)

In p a r a lle l c ir c u it s , t h e e le c t r ic a l d e v ic e s a r e c o n n e c t e d
b y p a r a lle l w ir e s th a t a r e jo in e d a t th e s ta r t o f th e c irc u it.
T h e c u r r e n t d iv i d e s : p a r t o f it f l o w s in t o o n e d e v ic e , p a r t
in to a n o th e r .
W it h c ir c u it s in p a r a l l e l, e a c h c ir c u it c a n b e s w it c h e d o n
a n d o ff b y its e lf s in c e e a c h c ir c u it r e c e iv e s e le c t r ic it y
d ir e c tly fr o m t h e p o w e r s u p p ly .
CIRCUIT COMPONENTS (Figure 2)

T h e u s u a l c ir c u it p a th s ta r ts a t t h e p o w e r s u p p ly w h ic h
is t h e b a t t e r y /g e n e r a t o r s y s t e m . N e x t in t h e c ir c u it is t h e
c ir c u it p r o te c tio n c o m p o n e n t w h ic h c a n b e a fu s ib le lin k , a
fu s e , o r a c ir c u it b r e a k e r . T h e n th e c ir c u it g o e s to th e
c ir c u it c o n t r o lle r w h ic h c a n b e a s w it c h o r a r e la y . F r o m
CAB ELECTRICAL 8A-3

closes the contacts. So the circuit breaker opens and
closes until the excess current condition is corrected or
the circuit is disconnected from the power supply.
The remote reset circuit breaker has a heating wire
wound around the bimetallic strip. When an excess
current happens, the strip heats, bends, and opens the
contacts. Then a small current flows through the heat
wire, keeping the strip hot and the contacts open. This
type of breaker will stay open until either the power supply
is disconnected from the circuit or the breaker is removed
from the circuit. Then the breaker can cool and reset.
CIRCUIT CONTROLLERS
Figure 2C ircuit Components

the circuit controller the circuit goes into the circuit load.
The circuit load can be one light or many lights in parallel,
an electric motor or a solenoid. After the electricity has
passed through the load it must return to the power
supply via the ground path. The ground path can be a
wire in the harness or it could be through the load
housing into the body or frame, thus returning the
electricity to the power supply. The body and frame are
connected by flexible ground straps.
FUSIBLE LINK
A fusible link is a section of wire that is usually four
gage sizes smaller than the circuit it protects. A special
insulation is used that swells when heated by the wire.
Fusible links are usually found in the engine compartment
harnesses. The function of the fusible link is to melt open
when an overload occurs, thus preventing any damage to
the circuit.
FUSES
The most common protector in the vehicle circuit is a
fuse. A fuse consists of a fine wire or strip of metal inside
a glass tube or plastic housing. The strip melts and
interrupts the flow of current in the circuit when there is an
overload caused by an unwanted short or ground. The
fuse is designed to melt before the wiring or electrical
components in a circuit can be damaged. Naturally, the
cause must be located and corrected before the fuse is
replaced or the new fuse will also blow.
Since different circuits handle different amounts of
current, fuses of various ratings are used. Fuses are rated
in amperes. Be sure to replace a blown fuse with a fuse of
the connecting rating.
CIRCUIT BREAKERS
Circuit breakers are another form of circuit protector.
There are two types of circuit breakers; automatic reset
and remote reset.
The automatic reset breaker opens when excess
current heats a bimetallic strip, causing the strip to bend
and open a set of contacts. Then the strip cools and
C ircuit controllers consist of switches or relays.

Switches are usually operated by a mechanical means
such as a hand or lever. Switches are usually at the
beginning of a circuit but can be used to control a ground
path. For example, the switch controlling the headlights is
at the power end of the circuit while the door switch
controlling the domelight completes the ground path.
Relays are remotely controlled switches. They are used
in high current circuits and in circuits controlled by
sensors.
Relays are designed so that a small current circuit will
be able to control a large current circuit.
WIRING HARNESS AND WIRES

Every wire is a specific size with colored or striped
insulation that is indicated on the wiring diagrams.
Insulation colors help to trace circuits and to make proper
connections. A bbreviations and sym bols used for
indicating wire insulation colors and patterns are as
follows:
B L K ............... .................. B l a c k
B R N ............... .................. B r o w n
C H K ............... ............... C h e c k
P P L ............... ............... P u r p l e
T R .................. .................. T r a c e r
Y E L ............... ............... . Y e l l o w
C R ............... .................. C r o s s
G R N ............... .................. G r e e n
/ / .................. ............ P a r a l l e l
W H T ............ .................. W h i t e
B L U ............ ...................... B l u e
S T R ............... .................. S t r i p e
P N K ............ ...................... P i n k
D K .................. ..................... D a r k
N A T ............ ............... N a t u r a l
S G L ............... .................. S i n g l e
O R N ............ ............... O r a n g e
G R ............... ......................G r a y
Some wires are grouped and taped together or

encased in a split plastic casing. This grouping of wires is
called a harness. For some purposes, it is more practical
to use a single wire protected by a braided tubing called a
loom.
Wiring harnesses are joined by using a multiple plug
and receptacle connector block, or a terminal post
chassis junction block. In the instrument panel area
plastic insulated blade-type connectors and screw-type
terminals are used.
Each harness or wire must be held securely in place by
clips or other holding devices to prevent chafing of the
insulation.
WIRE SIZE
Wire size in a circuit is determined by the amount of
current, the length of the circuit and the voltage drop
allowed. Wire size is specified using the metric gage. The
metric gage describes the wire size directly in cross
section area measured in square millimeters.
8A-4 CAB ELECTRICAL
B -0 0 7 2 4
Figure 3Open Circuit
Figure 4Short C ircuit
WIRE SIZE CONVERSION TABLE
a ls o b e c a u s e d b y d e p o s its o f o il, d ir t a n d m o is t u r e
a r o u n d c o n n e c t io n s o r te r m in a ls , w h ic h p r o v id e a g o o d
p a th to g r o u n d .-
METRIC
SIZE
(mm)2
AWG
SIZE
0 .2 2
24
0 .5
0 .8
20
18
1 .0
2 .0
3 .0
16
14
12
5 .0
8 .0
1 3 .0
1 9 .0
3 2 .0
4 0 .0
5 0 .0
10
8
6 2 .0
00
CIRCUIT DIAGNOSIS
A c le a r u n d e r s ta n d in g o f th e c ir c u it a n d a w ir in g
d ia g r a m a r e n e e d e d fo r e f f e c t iv e d ia g n o s is . U s e a lo g ic a l
s e q u e n c e o f te s tin g to fin d t h e t r o u b le . U s e t h e d ia g n o s tic
to o ls . A fte r t h e
w o rk s c o rr e c tly .
6
4
2
1
OPEN CIRCUIT (Figure 3)

A n o p e n c i r c u i t o c c u r s w h e n e v e r t h e r e is a b r e a k in t h e
c ir c u it. T h e b r e a k c a n b e c o r r o s io n a t th e c o n n e c to r , a
w ir e b r o k e n o f f in a d e v ic e , o r a w ir e t h a t b u r n e d
fro m to o m u c h c u rre n t.
open
SHORT CIRCUIT (Figure 4)

h e n th e c u rre n t b y p a s s e s p a rt
y p a s s in g is u s u a lly c a u s e d b y
in o r o n a d e v ic e s u c h a s a
s o ld e r m e ltin g a n d b r id g in g
c o n d u c t o r s in a d e v ic e .
GROUNDED CIRCUIT (Figure 5)

s h o r t c irc u it
c ir c u it t h a t is
e caused by
S o m e tim e s a
s u re
th e
c irc u it
T h is to o l c o n s is ts o f a 1 2 v o lt la m p w ith le a d s . T h e e n d s
o f t h e le a d s u s u a lly h a v e a llig a t o r c la m p s , b u t v a r io u s
k in d s o f p r o b e s , te r m in a l s p a d e s , a n d s p e c ia l c o n n e c to r s
a r e u s e d a ls o .
A g r o u n d c ir c u it is lik e a
flo w s d ir e c tly in to a g r o u n d
o rig in a l c ir c u it. T h is m a y b
a g a in s t th e f r a m e o r b o d y .
m ake
UNPOWERED TEST LAMP
T h e r e a r e t h r e e e le c t r ic a l c o n d itio n s t h a t c a n c a u s e a
n o n w o r k in g c ir c u it; a n O p e n C ir c u it , a S h o r t C ir c u it ,
a n d a G r o u n d C ir c u it.
u it h a p p e n s w
c ir c u it. T h is b
g , s a lt w a te r
c o n n e c to r o r
is f ix e d ,
DIAGNOSTIC TOOLS
CIRCUIT MALFUNCTIONS
A s h o r t c irc
o f th e n o rm a l
w ir e s to u c h in
s w itc h o r a
tr o u b le
b u t th e c u rre n t
n o t p a rt o f th e
a w ir e r u b b in g
w ir e w ill b r e a k
a n d fa ll a g a in s t m e t a l t h a t is c o n n e c t e d e le c t r ic a lly to t h e
g r o u n d s id e o f t h e p o w e r s u p p ly . A g r o u n d c ir c u it m a y
T h e u n p o w e r e d t e s t la m p is u s e d o n
O n e le a d o f t h e t e s t la m p is g r o u n d e d a n
is m o v e d a r o u n d t h e c ir c u it t o f in d t h e o
o n th e p h y s ic a l la y o u t o f th e c ir c u it, s o m
e a s ie r to s ta r t a t th e p o w e r s u p p ly a n d
e a s ie r to s ta r t a t th e c ir c u it lo a d o r g r o u n
an open
d th e o th
pen. D ep
e t i m e s it
o th e r tim
d c ir c u it.
c irc u it.
e r le a d
e n d in g
w ill b e
e s it is
POWER TEST LAMP

T h is la m p is a p e n c il s h a p e d u n it w it h a s e lf c o n t a in e d
b a tt e r y , a 1 .5 v o l la m p b u lb , a s h a r p p r o b e a n d a g r o u n d
le a d f it t e d w it h a n a llig a t o r c lip .
CAB ELECTRICAL 8A-5

33
30.
31.
32.
33.
34.
P
C
S
A
L
o w e r S o u rc e
ir c u it B re a k e r
w it c h (C lo s e d )
m m e te r
oad
41.
42.
43.
44.
B-06086
m a in ly fo r te s tin g c o m p o n e n ts
th a t a r e d is c o n n e c te d fr o m t h e v e h ic le p o w e r s u p p ly . T h e
p o w e r t e s t la m p is a ls o u s e f u l f o r t e s t in g s u s p e c t e d h ig h
r e s i s t a n c e p o i n t s in a c i r c u i t s u c h a s c o n n e c t o r s a n d
g r o u n d c ir c u its t h a t a r e c o r r o d e d o r lo o s e .
JUMPER
T h e j u m p e r is
A v e r s io n o f th e
A m p fu s e . T h is
j u m p e r is c o n n e
T
end
th e
la m
usu
ju m
w ill
c te d
a lly a lo n g w ir e w ith a llig a to r c la m p s .

p e r h a s a f u s e h o l d e r in it w i t h a 1 0
p r e v e n t d a m a g i n g t h e c i r c u i t if t h e
in t h e w r o n g w a y .
h e j u m p e r is u s e d t o l o c a t e o p e n s in a c ir c u it . O n
o f t h e j u m p e r is a t t a c h e d t o a p o w e r s o u r c e a n d t h e
o t h e r e n d is a t t a c h e d t o t h e l o a d in t h e c ir c u it , i .e
p , m o to r . If t h e lo a d w o r k s , t r y j u m p i n g to c ir c u
B-07497
Figure 7Ohmmeter C ircuit
Figure 6Am m eter Circuit

T h i s t e s t la m p is u s e d
Circuit Breaker
Switch (Open)
Ohmmeter
Load
e
n
.;
it
p o in ts t h a t a r e p r o g r e s s iv e ly c lo s e r to t h e p o w e r s u p p ly .
W h e n th e c ir c u it lo a d s to p s w o r k in g , th e o p e n h a s b e e n
lo c a te d .
T h e j u m p e r is a ls o u s e d t o t e s t c o m p o n e n t s in t h e
c ir c u it s u c h a s c o n n e c t o r s , s w it c h e s , a n d s u s p e c t e d h ig h
r e s is t a n c e p o in ts .
NOTICE: The following instruments: Ammeter,

Voltmeter, and Ohmmeter, each have a
particular application for trouble shooting
electrical circuits.
Whenusinganammeteror voltmeter, andthe
value being tested is unknown, always use the
highest scale first and work downward to a
midscale reading whenever possible. This will
avoiddamageto theinstrument.
Never useanohmmeter in apower circuit, or
as asubstitute for a voltmeter or ammeter, as
damageto theinstrument will result.
AMMETER (Figure 6)
D is c o n n e c t th e c ir c u it fr o m th e p o w e r s o u r c e b e fo r e
c o n n e c tin g th e a m m e te r. T h e a m m e te r m e a s u r e s th e
a m o u n t o f e le c tr ic a l c u r r e n t, a m p e r e s , m o v in g th r o u g h a
c o n d u c to r . T h e a m m e t e r m u s t b e p la c e d in .s e r ie s w ith th e
c i r c u i t b e i n g t e s t e d . B e s u r e t h a t t h e a m m e t e r s p o s i t i v e
t e r m in a l is c o n n e c t e d to t h e p o s it iv e ( b a t t e r y ) s id e o f t h e
c i r c u i t a n d t h e a m m e t e r s n e g a t i v e t e r m i n a l i s c o n n e c t e d
to th e n e g a t iv e (g r o u n d ) s id e o f th e c irc u it.
OHMMETER (Figure 7)
T h e o h m m e t e r is a n in s t r u m e n t d e s ig n e d t o in d ic a t e
r e s i s t a n c e in o h m s . It is u s e d t o t e s t t h e c o n d i t i o n o f a u n i t
d is c o n n e c te d fr o m th e c ir c u it.
Ohmmeter Calibration
W h e n th e o h m m e te r p ro b e s a r e c o n n e c te d to g e th e r, a
c ir c u it is c o m p le t e d c a u s in g t h e m e t e r n e e d l e to d e f le c t .
T h e n e e d l e s h o u l d r e a d Z E R O o h m s , if it d o e s n o t , r o t a t e
th e C A L o r A D J k n o b to Z E R O th e n e e d le .
W h e n t h e p r o b e s a r e h e ld a p a r t , t h e n e e d le m o v e s to
t h e m a x im u m (in fin ite ) r e s is ta n c e s id e o f th e s c a le .
T h e m e t e r is n o w r e a d y fo r u s e .
VOLTMETER (Figure 8)
T h e v o lt m e t e r ( p r o p e r ly o b s e r v e d ) w ill g iv e t h e
t e c h n ic ia n m o r e in fo r m a tio n th a n t h e a m m e te r , o h m m e t e r
an d
te s t
la m p
c o m b in e d .
Its
a p p lic a tio n
fo r
8A-6 CAB ELECTRICAL
60. Connector
61. Terminal
B -0 6 1 5 6
Figure 9Removing Terminal

t r o u b le s h o o t in g h e r e is to m e a s u r e t h e e le c t r ic a l p r e s s u r e
( v o lt a g e ) d r o p in a r e s is t a n c e c ir c u it .
T o u s e a v o lt m e t e r fo r t r o u b le s h o o tin g a n e le c tr ic a l
p r o b l e m , c o n n e c t it in p a r a l l e l w i t h t h e e x i s t i n g c i r c u i t . If
t h e v o lt m e t e r is c o n n e c t e d in s e r i e s w i t h t h e c i r c u i t b e in g
te s te d , th e n a tu r e o f th e c ir c u it w o u ld b e c h a n g e d a n d th e
r e a d in g w o u ld h a v e n o p a r tic u la r v a lu e o r u s e . C o n n e c t
th e m e te r t e r m in a ls a c c o r d in g to p o la r ity a s s h o w n .
T h e d a s h m o u n t e d v o lt m e t e r (in t h e v e h ic le ) s h o u ld
a ls o b e o b s e r v e d fo r m o n ito r in g p r o p e r o p e r a tio n o f th e
g e n e r a t o r b a t t e r y c r a n k in g m o t o r , a n d c r a n k in g c ir c u it . In
th is a p p lic a tio n , b a t t e r y v o lt a g e d r o p c a n b e m o n ito r e d
w h il e t h e e n g i n e is c r a n k i n g ; a n d a f t e r t h e e n g i n e is
r u n n in g , g e n e r a t o r o u tp u t v o lta g e c a n b e m o n ito r e d . T h is
c a n b e a v a lu a b le firs t s te p p r io r to d ia g n o s in g o th e r
e le c tr ic a l p r o b le m s .
A ll e le c t r ic a l c o n n e c t io n s m u s t b e k e p t c l e a n a n d t ig h t .
L o o s e o r c o r r o d e d c o n n e c tio n s m a y c a u s e a d is c h a r g e d
b a tte r y , d iffic u lt s t a r t in g , d im la m p s , a n d p o s s ib le d a m a g e
t o t h e g e n e r a t o r a n d r e g u l a t o r . W i r e s m u s t b e r e p l a c e d if
in s u la tio n b e c o m e s b u r n e d , c r a c k e d , o r d e t e r io r a t e d .
T o s p lic e a w ir e o r r e p a ir o n e t h a t is f r a y e d o r b r o k e n ,
a lw a y s u s e r o s in flu x s o ld e r to b o n d t h e s p lic e a n d
s iz e
s or
l y in
due
to v ib r a tio n .
Never replace a wire with one of a smaller size or

replace a fusible link with a wire of a larger size.
WIRING CONNECTOR TERMINAL
REPLACEMENT (BLADE TYPE)
|<"| Remove or Disconnect (Figure 9)
1. T e r m in a l lo c k ta n g .
2 . T e rm in a l (6 1 ).

1. P ry u p o n th e ta n g (7 0 ).
2 . T e r m in a l in to t h e c o n n e c to r .
Figure 10Resetting the Lock Tang

WIRING CONNECTOR TERMINAL
REPLACEMENT (TWIN LOCK TYPE)
J -2 2 7 2 7 T e r m in a l R e m o v e r
1. C o n n e c to r lo c k ta n g s .
2 . T e r m in a l lo c k s u s in g J - 2 2 7 2 7 .
3 . T e r m in a l.
Install or Connect
METRI-PACK CONNECTOR
REPLACEMENT
MAINTENANCE AND REPAIR
in s u la tin g t a p e to c o v e r a ll s p lic e s o r b a r e w ir e s .
W h e n r e p l a c i n g w i r e , it is i m p o r t a n t t h a t t h e c o r r e c t
w ir e b e u s e d a s s h o w n o n a p p lic a b le w ir in g d ia g r a m
p a r ts b o o k . E a c h h a r n e s s o r w ir e m u s t b e h e ld s e c u r e
p la c e to p r e v e n t c h a f in g o r d a m a g e to th e in s u la tio n
B -0 6 2 2 7
1. P ry o u t th e ta n g s .
2 . T e r m in a l in to th e c o n n e c to r.
CIRCUIT MAINTENANCE
AND REPAIR
71
70. Term inal Lock Tang

71. Term inal

J -3 5 6 8 9 -A T e r m in a l R e m o v e r
1 . P r im a r y lo c k ( 1 2 1 ) b y liftin g .
CAB ELECTRICAL 8A-7
190
121
122
VIEW B
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
C onnecto r Seal
Prim ary Lock
Secondary Lock Staple
Secondary Lock
Terminal Barrel
Secondary Lock
Lock Opened
Lock Opened
J-28742 Terminal Remover
Wire
130.
131.
132.
133.
134.
136.
137.
138.
139.
5 mm (0.2 inch)
Terminal
Roll C rim p
Roll C rim p
Terminal Insulator
Metri-Pack Series 150 Fem ale Terminal
C onnecto r Body
Locking Tang
J-35689 Terminal Remover
F-02349
Figure 12Weather-Pack and Metri-Pack Connectors
8A-8 CAB ELECTRICAL
90 91
101
100 \
92
nn //(Lr/
90.
91.
92.
93.
94.
95.
Jacket
Twisted W ires
S plice C lip
C rim p and S older
E lectrical Tape W rap
O uter E lectrical Tape Wrap.
106
AXW W \
Figure 13Twisted Lead Repair

2 . C o n n e c to r b o d y (1 3 7 ).
3 . C o n n e c t o r s e a l ( 1 2 0 ) b y p u llin g t h e s e a l b a c k o n to
th e w ir e s a w a y fr o m th e c o n n e c to r b o d y (1 3 7 ).
4 . T e r m in a l (1 3 6 ) b y in s e r tin g J - 3 5 6 8 9 (1 3 9 ) in to th e
c o n n e c to r b o d y (1 3 7 ) to d e p r e s s th e lo c k in g ta n g
(1 3 8 ), th e n p u s h th e w ir e a n d te r m in a l th r o u g h th e
c o n n e c to r b o d y (F ig u r e 1 2 ).
S n ip o f f t h e o ld t e r m in a l u n le s s t h e t e r m in a l is t o b e
r e u s e d , r e s h a p e th e lo c k in g ta n g .
5 . 5 m m (0 .2 - in c h ) o f t h e w ir e in s u la tio n (1 3 0 ).
IJI
107
B -0 6 2 3 0
Clean
T e r m in a l c a v ity o f th e c o n n e c to r b o d y .

1 . T e r m in a l (1 3 6 ) o n t h e w ir e .
C r im p a n d s o ld e r t h e te r m in a l.
2 . T e r m in a l ( 1 3 6 ) in to t h e c o n n e c t o r c a v ity b y p u llin g
t h e w ir e o n t h e s e a l s id e o f t h e c o n n e c to r u n til th e
lo c k in g t a n g ( 1 3 8 ) is f u lly s e a t e d .
3 . S e a l ( 1 2 0 ) b y p r e s s in g t h e s e a l in to t h e c o n n e c t o r
b o d y ( 1 3 7 ) u n t il it is f u ll y s e a t e d .
4 . C o n n e c t o r u n til t h e p r im a r y lo c k (1 2 1 ) e n g a g e s .
WEATHER-PACK CONNECTORS (Figure
100.
101.
102.
103.
104.
105.
106.
Jack et
A lu m in u m /M y la r T a p e
D ra in W ir e
S p lic e C lip
C r im p a n d S o ld e r
E le c tr ic a l T a p e W r a p
D r a in W ir e S p lic e C lip , C r im p e d
d e re d .
1 0 7 . O u t e r E le c tr ic a l T a p e W r a p .
A nd
S o l
B -0 6 2 3 1
Figure 14Twisted/Shielded Lead Repair

M a k e s u re th a t th e c o n n e c to r s a r e p ro p e r ly s e a te d a n d
a ll o f t h e s e a l i n g r in g s a r e in p l a c e w h e n c o n n e c t i n g t h e
le a d s . T h e h in g e -ty p e fla p p r o v id e s a b a c k -u p , o r
s e c o n d a r y lo c k in g fe a t u r e fo r t h e te r m in a ls . T h e y a r e
u s e d to im p r o v e t h e c o n n e c to r r e lia b ility b y r e ta in in g th e
t e r m in a l s if t h e s m a ll t e r m in a l lo c k t a n g s a r e n o t
p o s itio n e d p ro p e rly .
M o ld e d -o n -c o n n e c to r s r e q u ir e c o m p le te r e p la c e m e n t o f
t h e c o n n e c tio n . T h is m e a n s s p lic in g a n e w c o n n e c to r
a s s e m b ly
c a n n o t b
In s tr u c tio
c o n n e c to r
in to
e r
n s
and
th e
e p la
a re
te rm
h a r n e s s . E n v ir o n m e n ta l c o n n e c tio n s
c e d w ith s t a n d a r d c o n n e c tio n s .
p r o v id e d w ith th e W e a t h e r - P a c k
in a l p a c k a g e s .
12)
S p e c ia l c o n n e c to r s k n o w n a s W e a th e r -P a c k c o n n e c to rs
r e q u ir e a s p e c ia l to o l J - 2 8 7 4 2 fo r s e r v ic in g . T h is s p e c ia l
W it h t h e lo w c u r r e n t a n d v o lt a g e le v e ls f o u n d in s o m e
c i r c u i t s , it is i m p o r t a n t t h a t t h e b e s t p o s s i b l e b o n d a t a ll
w ir e s p lic e s b e m a d e b y s o ld e r in g t h e s p lic e s .
t o o l is r e q u ir e d t o r e m o v e t h e p in a n d s l e e v e t e r m in a l s . If
r e m o v a l is a t t e m p t e d w it h a n o r d in a r y p ic k , t h e r e is a
g o o d c h a n c e t h a t t h e t e r m in a l w ill b e b e n t o r d e f o r m e d .
U n lik e s ta n d a r d b la d e - t y p e te r m in a ls , t h e s e te r m in a ls
c a n n o t b e s tr a ig h te n e d o n c e th e y a r e b e n t.
U s e c a r e w h e n p ro b in g th e c o n n e c tio n s o r r e p la c in g
t e r m i n a l s in t h e m , it is p o s s i b le t o s h o r t b e t w e e n o p p o s it e
t e r m i n a l s . If t h i s h a p p e n s t o t h e w r o n g t e r m i n a l p a r t , it is
p o s s ib le th a t d a m a g e m a y b e d o n e to c e r t a in
CAB ELECTRICAL 8A-9

c o m p o n e n ts .
A lw a y s
u se
ju m p e r
w ir e s
b e tw e e n
c o n n e c to r s fo r c irc u it c h e c k in g . N e v e r p r o b e th r o u g h th e
W e a t h e r - P a c k s e a ls .
W h e n d i a g n o s i n g f o r p o s s i b le o p e n c i r c u it s , it is o f t e n
d iffic u lt to
t e r m in a l
M e re ly w
h a rn e s s
s h o u ld a
in d ic a te d
lo c a te
th e m
by
s ig h t
because
o x id a tio n

J -2 8 7 4 2 T e r m in a l R e m o v e r
P r im a r y lo c k (1 2 1 ) b y liftin g .
o n n e c to r s e c tio n s .
e c o n d a r y lo c k (1 2 5 ) b y s p r e a d in g th e s id e s o f th e
a s p , th u s c le a r in g th e s ta p le s a n d r o ta tin g th e
a s p (1 2 7 ).
T e r m in a l (1 3 1 ) b y u s in g J - 2 8 7 4 2 (1 2 8 ) .
S n ip o ff t h e o ld t e r m in a l a s s e m b ly .
5. 5 m m
T h e
w ire
r e p a ir
is
v e ry
im p o r ta n t fo r th e
c o n tin u e d
r e lia b le o p e r a tio n o f th e v e h ic le . T h is r e p a ir m u s t b e d o n e
a s d e s c r ib e d in t h e f o llo w in g p r o c e d u r e s .
or
m is a lig n m e n t a r e h id d e n b y t h e c o n n e c to r s .
i g g l in g a c o n n e c t o r o n a s e n s o r o r in t h e w i r i n g
m a y c o r r e c t t h e o p e n c ir c u it c o n d itio n . T h is
l w a y s b e c o n s i d e r e d w h e n a n o p e n c i r c u i t is
w h ile t r o u b le s h o o tin g . In te r m itte n p r o b le m s m a y
a ls o b e c a u s e d b y o x id iz e d o r lo o s e c o n n e c tio n s .
C
S
h
h
WIRING REPAIR
o f th e w ir e in s u la tio n (1 3 0 ).
Clean
T e r m in a l B a rr e l (1 2 4 ).

T e r m in a l in s u la to r ( 1 3 4 ) o n th e w ir e . S lid e th e
in s u la to r b a c k o n t h e w ir e a b o u t 8 c m (3 in c h e s ).
T e r m in a l (1 3 1 ) o n th e w ir e .
R o ll c r im p (1 3 2 ) a n d s o ld e r t h e te r m in a l.
T e r m in a l in s u la t o r ( 1 3 4 ) a n d r o ll c r im p ( 1 3 3 ) .
T e r m in a l in to t h e c o n n e c t o r .
S e c o n d a r y lo c k (1 2 5 ).
C o n n e c t o r s e c t io n s u n til t h e p r im a r y lo c i (1 2 1 )
Twisted Leads (Figure 13)

1. J a c k e t (9 0 ).
2 . T w is te d w ir e s ( 9 1 ) .
3 . In s u la tio n fr o m t h e w ir e .
Install or Connect
1 . S p lic e c lip ( 9 3 ) .
C r im p .
S o ld e r .
2 . E le c tr ic a l t a p e w r a p ( 9 4 ) o n w ir e s .
3 . O u t e r e le c tr ic a l t a p e w r a p (9 5 ).
Twisted Leads/Shielded Cable (Figure 14)

[+ [ Remove or Disconnect
1. J a c k e t (1 0 0 ).
2 . U n w r a p a lu m in u m /m y la r ta p e (1 0 1 ).
3 . D r a in w ir e (1 0 2 ).
4. Leads.
5 . In s u la tio n o n t h e le a d s .
1.
2.
3.
4.
5.
S p lic e c lip s (1 0 3 ).
C r im p a n d s o ld e r t h e s p lic e c lip s ( 1 0 4 ).
E le c t r ic a l t a p e ( 1 0 5 ) o n t h e s p lic e s .
A lu m in u m /m y la r t a p e b y w r a p p in g a n d t a p in g .
D r a in w ir e w ith a s p lic e c lip (1 0 6 ). C r im p a n d s o ld e r
t h e s p lic e c lip .
6 . O u t e r ja c k e t e le c tr ic a l t a p e w r a p (1 0 7 ).
engages.
CAB ELECTRICAL SYSTEMS

RV CAB HARNESS ROUTINGS
T h e r e a r e s e v e r a l w irin g h a r n e s s e s r o u te d th r o u g h o u t
t h e c a b w h ic h p r o v id e c o n tin u ity b e t w e e n t h e e le c tr ic a l
c o m p o n e n ts . T h e s e h a r n e s s e s c o n s is t o f: th e in s tr u m e n t
p a n e l h a r n e s s , th e p o w e r d o o r lo c k s a n d p o w e r w in d o w
h a r n e s s , th e r a d io h a r n e s s , th e h e a t e r h a r n e s s e s , th e a ir
c o n d itio n in g
h a r n e s s e s a n d th e in te r io r lig h tin g
h a rn e s s e s .
INSTRUMENT PANEL HARNESS (Figure 15)

T h i s h a r n e s s is l o c a t e d a l o n g t h e u p p e r b a c k e d g e o f
t h e i n s t r u m e n t p a n e l . It s t a r t s f r o m t h e f u s e p a n e l w h ic h is
lo c a te d a t t h e le ft s id e o f t h e d a s h p a n e l, a n d g o e s u p to
th e le ft s id e o f th e in s tr u m e n t p a n e l a n d a c r o s s th e
in s t r u m e n t p a n e l to t h e r ig h t s id e o f t h e c a b .
A s t h e in s t r u m e n t p a n e l h a r n e s s is r o u t e d a c r o s s t h e
in s t r u m e n t p a n e l, v a r io u s c ir c u its b r a n c h o ff to th e
s w it c h e s , in d ic a to r s , a n d t h e in s t r u m e n t p a n e l. T h e
h a r n e s s is h e ld in p la c e w it h b e n d a b l e c lip s .
O
th e
th e
con
t h e r h a r n e s s e s a r e c a r r i e d in t h e s a m e s u p p o r t s a s
in s tr u m e n t p a n e l h a r n e s s . T h e s e h a r n e s s e s c o n s is t o f
p o w e r d o o r lo c k s , p o w e r w in d o w , r a d io , h e a t e r a n d a ir
d itio n in g .
POWER DOOR LOCKS AND POWER WINDOWS

HARNESS (Figures 16 and 17)
T h is h a r n e s s s ta r ts a t t h e fu s e b lo c k a n d r o u te s to th e
le ft a n d r ig h t a lo n g t h e in s t r u m e n t p a n e l. A t t h e m id d le o f
th e in s tr u m e n t p a n e l, th e h a r n e s s b r a n c h e s o ff to th e
r e la y a s s e m b ly . T h e r e la y a s s e m b l y is lo c a t e d o n t h e
in s id e o f th e d a s h p a n e l, ju s t a b o v e th e s te e r in g c o lu m n .
T h e h a r n e s s th e n g o e s to a s e t o f c o n n e c to rs o n th e in n e r
w h e e l h o u s in g . F ro m th e c o n n e c to r s th e h a r n e s s p a s s e s
t h r o u g h a g r o m m e t in t h e f r o n t d o o r o p e n i n g t r im p a n e l
a n d th e n th r o u g h a f le x ib le c o u p lin g to t h e d o o r. In s id e
th e d o o r
th e d o o r
h a rn e s s
w ith r e ta
th e h a r n e s s b r a n c h e s o ff to th e c o n tr o l s w itc h e s ,
lo c k m o to r s , a n d th e p o w e r w in d o w m o to r s . T h e
c o n n e c to r s a r e fa s te n e d to th e c o n tr o l s w itc h e s
in in g n u ts .
8A-10 CAB ELECTRICAL
1. H eater C ontrol Lamp Bulb

2 . H eater C onnector
3. In strum e n t Panel C lu ste r C onnector

4. In strum e n t Panel G round C onnector
5. G round C onnecto r
6. Ground C irc u it W ire
7. Main Lam p S w itch C onnector
8. Engine F un ction D iagnosis C onnector
9. D oor Jam b & Dome Lamp C onnector
. Parking Brake S w itch C onnecto r
11. Dash Panel C onnector
12. Horn Relay
13. Dome Lam p And D oor Jam b Harness C onnector
14. C onvenience C enter
15. Radio C o nn e cto r
16. C igarette Ligh ter C onnector
17. C ourtesy Lamp
10
F-00728
Figure 15RV Instrument Panel Harness
CAB ELECTRICAL 8A -11
20.
21.
22.
23.
24.
25.
26.
In stru m en t Panel Harness

Power Lock And W in do w Harness
Door H arness C o n ne cto r
Power W indow C o n ne cto r
Ground
Fuse B lock
Power Lock C on ne cto r
27.
28.
29.
30.
31.
32.
33.
Power W indow C o nnecto r

Dash Panel C o nnecto r
Power Door Lock Relay
Brake Pedal Bracket
Side Front Door Harness
Rear Panel Door H arness C onnector
Rear Panel D oor Power Lock C onnector
F-00729
Figure 16RV Power Door Locks and Window Harnesses
39.
40.
41.
42.
43.
44.
45.
46.
47.
N ut
P ow er W in d o w S w itc h C o n n e c to r
R e ta in e r Bezel
P ow er W in d o w S w itc h
P ow er D o o r L ock S w itc h C o n n e c to r
R e ta in e r Bezel
P ow er D o o r L ock S w itc h
P ow er D o o r L ock M o to r
P ow er W in d o w M o to r
48. F ro n t D o o r H a rn e ss
Figure 117 RV Door W iring
F-00730
CAB ELECTRICAL 8A-13
60.
61.
62.
63.
F use B lo ck
P ow er D oo r L ock S w itc h
L ock M o to r
Pop R ivet
F-00731
Figure 18RV Rear Door Lock Harness
Figure 19Cargo Lamp Harness

REAR DOOR POWER LOCK HARNESS (Figure 18)
The rear doors power lock harness starts at a connector
in the fuse block. The harness is routed along the
instrument panel harness, with a branch going to the
power door lock switch assem bly in the instrument panel.
The harness then drops down the right front door hinge
frame and routes back alon the right door sill to the right
front door latch frame. The harness then travels up the
right front door latch fram e to its m idpoint where a
connector is located. The harness then goes to the roof
halo panel and back to the rear door frame.
At the rear door frame, the harness is connected to a
contact assembly on the right rear door frame. This
contact assembly is aligned with a contact assembly
m ounted on the rig h t rear door. From the co n ta ct
assembly on the door, the harness then goes to the lock
motor.
CARGO LAMP HARNESS (Figure 19)

The harness starts from the instrum ent panel harness
and routes under the left front door sill. The harness then
goes up the left front door latch fram e, through a
connector, and into a control switch.
From the control switch, the harness goes down the
frame, back along the rear door sill and then up the rear
door latch frame. From the top of the frame the harness
goes to the cargo lamp.
RV FUSE BLOCK
The fuse block holds the fuses and circuit breakers that
protect the circuits. The fuse block is located on the left
side of the dash panel and is fastened to the dash panel
connector block with two screws. The fuse panel connects
to the engine com partm ent harness. Power leads from the
various circuits plug into the fuse block.
The fuses are encased in plastic and have twin blade
connectors. The fuses are printed and color coded with
the amperage rating. Refer to Figure 20.
(3
jg A U X HEAT
A /C /
0 E
I]
REAR DOOR POWER LOCK CIRCUIT (Figure 25)
0 E 0 0 )
ACC
B ATT
LPS
PWR
30
C IR /B R K
ECM !*
[XI
CRANK*
C=3
front door latch frame, where it connects to the door frame

contact assembly. The door fram e contact assem bly
aligns with the door contact assembly so that electrical
contact is made when the door is closed. In this way,
electricity is conducted to the side door power lock motor.
o \
C
* N o t on D iesel E n g in e e q u i p p e d ve h icle s.
B-07656
The rear power door lock harness is routed from the

connector on the left front door hinge frame. The harness
goes up the frame to the roof, rearward along the roof
halo panel and then crosses over to the right rear corner,
using the rear roof halo panel. The harness goes down
the right rear corner to a connector just below the upper
door hinge. The harness then passes through grommets
and into the right rear door. Inside the door the harness
connects to the power lock motor.
POWER WINDOW SYSTEM

(Figures 22, 23, 24 and 25)
This harness starts at the fuse block and routes to the
left and right along the instrument panel. The harness
then routes into the left and right front doors. At the left
door hinge pillar, the harness routes up to the left roof
halo panel, back to the first roof frame, branches to the
right side of the van and rearward to the rear door. The
branch that went to the right side routed down the side
door hinge pillar and into the side door.
Figure 20RV Fuse Block

INTERIOR LIGHTING SYSTEM (Figures 26 and 27)
G VAN CAB HARNESS ROUTINGS

INSTRUMENT PANEL HARNESS (Figure 21)
The instrum ent panel harness in the G van includes the
circuits for the instrument panel gages, indicators, main
ligh t sw itch, w indshield w iper and washer, and the
steering column controls. The harness is held in place
with clips that plug into brackets which are mounted on
the instrum ent panel.
FRONT DOOR POWER LOCK SYSTEM

(Figure 22 and 23)
The harness starts from the fuse block, which is located
under the far left side of the instrum ent panel. The left
branch of the harness has a connector at the left door
hinge frame. Then the harness passes into the frame and
routes down to a flexible conduit to the door. Inside the
door, the harness branches; one branch going down to
the door lock motor, and the other branch going up to the
door lock switch.
The right branch of the harness routes across the top of
the instrum ent panel to the right door hinge frame. The
harness passes through a connector and continues into
the door frame. The harness routes down to a flexible
conduit. The harness passes through the flexible conduit
into the door. Inside the door, the harness branches; one
branch going up to the door lock switch, and the other
branch going to the door lock.
SIDE DOOR POWER LOCK CIRCUIT (Figure 24)

The side door power lock circuit branches off from the
left roof halo harness just behind the front door latch
frame. It goes across the roof frame and down the right
This circuit starts at the fuse block and routes to the

body harness connector. The standard harness is then
routed up the left front door hinge frame and back along
the left roof halo panel. The harness branches at the first
and third roof frames, with connectors located next to the
left roof halo panel. The harnesses then go to the roof
lamps and term inate in bulb clips. The standard harness
also branches off to the door switches.
The optional harness is routed from the body harness
connector to a control switch on the instrument panel.
The harness then goes from the switch to the left front
door hinge frame, up the frame, and back along the left
roof halo panel.
When the harness reaches the first roof frame, it goes
into a connector. There are two branches coming out of
the connector. One branch goes to the center lamp
assembly in the roof. This branch, after connecting to the
center lamp assembly, continues on to the right side of
the roof, where it goes into a connector. From this
connector, one lead goes to the side door grounding
switch. The other leads are routed down the right front
door lock frame to the stepwell lamp assembly.
The o the r b ranch, co m ing out of the roof fram e
connector, goes back along the left roof halo panel,
across the rear halo panel and terminates at the rear door
ground switch. Also coming from this connector is a
branch that goes down the left front door lock frame to the
left stepwell lamp assembly.
71
70.
71.
72.
73.
74.
75.
76.
77.
H e a te r L am p C o n n e c to r
H e a te r C o n tro ls A s s e m b ly
In s tru m e n t C lu s te r C o n n e c to r (Telltale)
In s tru m e n t C lu s te r C o n n e c to r (Gages)
N e u tra l S w itc h (M a nu al T ra n sm issio n )
L ig h t S w itc h C o n n e c to r
B o d y W irin g H a rn e ss C o n n e c to r
H orn Relay
78. Park Brake S w itc h C o n n e c to r

79. Test C o n n e c to r
80. G ro u n d Bus
81.
82.
83.
84.
85.
86.
87.
88.
89.
B ack Up S w itc h C o n n e c to r
In s tru m e n t Panel H a rn e ss G ro u n d C o n n e c to r
S te e rin g C o lu m n C o n n e c to r
W in d s h ie ld W ip e r C o n n e c to r
S to p Lam p C o n n e c to r
S to p Lam p S w itc h
T orque C o n v e rte r C lu tc h C o n n e c to r
B lo w e r M o to r C o n n e c to r
W in d s h ie ld W ip e r A n d W a sh e r H a rn e ss C o n n e c to r
Figure 21Van Instrum ent Panel Harness
F-00734
104
100. P ow er Lock Relay
103. Pow er D o o r L ock C o n n e c to r
101. R ig h t D oor H a rne ss
104. G ro u n d C o n n e c to r
102. P ow er W in d o w C o n n e c to r 105. Power D o o r L ock C irc u it
106. P ow er W in d o w C irc u it B reaker

107. L e ft D o o r H arne ss
F-00735
Figure 22Van Power Door Lock and W indow Harness
G VAN FUSE BLOCK

The fuse block holds the fuses and circuit breakers that
protect the circuits. The fuse block is located on the left
side of the dash panel and is fastened to the dash panel
connector block with two screws. The fuse block connects
to the engine compartm ent harness. Power leads from the
various circuits plug into the fuse block.
The fuses are encased in plastic and have twin blade
connectors. The fuses are printed and color coded with
the amperage rating. Refer to Figure 28.
POWER DOOR LOCK SYSTEM

DESCRIPTION
Individual motors operate each door lock. The direction
the motor turns depends on the polarity of the supply
voltage. The door lock switches control the supply voltage
polarity. Each switch will lock all the doors.
Each motor has a self-resetting circuit breaker built in.

Voltage is present at the door lock switches at all times.
Voltage is also present on the open contacts of the door
lock relay at all times.
When a door switch is moved to Lock, current flows
through the switch and lock relay coil to ground. The relay
closes, causing current to flow through the lock relay
contacts, door lock motor, the unlock relay contacts, and
then to ground.
When a door lock switch is moved to U nlock, current
flows through the switch, the unlock relay contacts, the
door lock motor, the lock relay contacts, and to ground.
This causes the lock motor to unlock the door.
For RV models, the door lock relay is located on, the
dash panel, above the steering column. For G van models
the door lock relay is located on front left door hinge pillar.
Figure 23Van Front Door Harness
P ow er W in d o w M o to r C o n n e c to r
P ow er W in d o w M o to r
C o n ta c ts A s s e m b ly
Pow er W in d o w s H arne ss C o n n e c to r
P ow er L o ck M o to r C o n n e c to r
P ow er L o ck M o to r
135 134
F-00737
Figure 24Van Side Door Harness
Figure 25~ V a n Rear Door Harness
Figure 26Van Door Jamb Switch and Dome Lamp
Figure 27Van Interior Lighting Harness
BATT
"V
WDO
IGN
ACC
LPS
INST LPS
HO RN/DM
TAIL LPS
AUX HEAT
K ]
[M l
30A
PW R ACC
D 3 K ]
GAUGES
K ]
AUX HTR A/C
TURN/BU
HTR A/C
ECM 1
PW R WDO
r^ n
~ jc M B
30A
0]
FUSPLR
B-07570
Figure 28Van Fuse Block
DIAGNOSIS OF POWER DOOR LOCK SYSTEM

PROBLEM
One Door Lock Will
Not Work.
POSSIBLE CAUSE
1. No power at lock motor.
2. Open ground circuit between the motor

and the relay.
None of the Door

Locks Function; All
Switches Tried.
1. No power.
2. Relay not working.
CORRECTION
1. Check for voltage at the lock motor. If
no voltage at lock motor, check for volt
age at the connector which is located at
the front door hinge pillar. If there is no
voltage at the connector, check for an
open between the connector and the
door lock relay.
2. Move a door switch to Lock. Backprobe the TAN wire at the motor. If there
is voltage, find the open between the
motor and the relay.
1. C heck for power at the fuse block
(ORN/BLK). Check for power at the
door lock relay (ORN/BLK). If power is
p re s e n t at the fu s e b lo c k b u t not
present at the relay, find the open in the
harness.
2. Hold a switch to Lock. Backprobe the
LT BLU wire at the relay. If there is no
voltage, find the open in the harness. If
there is voltage, check the relay case to
ground path. If the ground is OK, check
the relay coil for conduction. If the relay
coil is OK, check for voltage on the TAN
wire. If there is no voltage, replace the
relay. If there is voltage, find the open
in the harness.
DIAGNOSIS OF POWER DOOR LOCK SYSTEM (CONT.)

PROBLEM
One Switch Wont
Lock the Doors.
POSSIBLE CAUSE
CORRECTION
1. No power to the switch.
1. Check for voltage on the ORN wire at

the switch. If there is no voltage, find
the open between the switch and the
fuse block.
2. Move the switch to Lock. Check for
voltage on the LT BLU w ire at the
switch. If there is no voltage, replace
the switch.
2. Switch has internal open.
ON-VEHICLE SERVICE
|-n-| Install or Connect

1.
2.
3.
4.
5.
POWER DOOR LOCK MOTOR REPLACEMENT

" Remove or Disconnect
1. Battery ground cable from the battery.
2. Door trim panel.
3. Motor. Refer to DOORS (SEC. 10A1).
POWER WINDOW SYSTEM
|-K-| Install or Connect

1. Motor. Refer to D O O R S (SEC. 10A1)
2. Door trim panel.
SWITCH REPLACEMENT
2. Door trim panel.
3. Switch connector. The connector is secured with a
retaining nut.
4. Switch. Press in both retaining tabs at the same
time.
Switch.
Switch connector.
Retaining nut.
Door trim panel.
DESCRIPTION
Each power window is moved by a single permanent
magnet motor. The direction the motor turns depends on
the polarity of the supply voltage. The control switches
control the supply voltage polarity.
Switches for controlling all the power windows are
located at the drivers door. Each passengers window
switch controls only the w indow at that passengers
position.
The motors have a self resetting circuit breaker built in.
The circuit breaker allows the motor to be stalled without
damage. There are no travel-limit switches.
When a window switch is moved to UP, current flows
through the circuit breaker, the window switch, the DK
BLU wire, the motor, the circuit breaker, the BRN wire, the
DN contacts in the switch, and into the BLK wire which
goes to ground.
DIAGNOSIS OF POWER WINDOW SYSTEM

PROBLEM
Passenger Window
Will Not Work, Using
Either Passenger
Switch or Driver
Switch.
POSSIBLE CAUSE
1. No power at the passenger switch.
2. Passenger switch is not working.
CORRECTION
1. Ignition switch at RUN or ACC. Check
for voltage at the PNK wire on the pas
senger switch. If there is no voltage,
find the open between the switch and
the fuse block.
2. With the voltage on the PNK wire at the
switch, move the switch to UP. There
should be voltage on the DK BLU wire
at the switch. If there is no voltage on
the DK BLU wire, replace the switch.
DIAGNOSIS OF POWER WINDOW SYSTEM (CONT.)

PROBLEM
POSSIBLE CAUSE
CORRECTION
Passenger Window
Will Not Work, Using
Either Passenger
Switch or Driver
Switch (Continued)
3. Motor has an internal open.
3. With the window switch moved to the

U P position, check for voltage on the
DK BLU wire at the motor. If there is no
voltage, find the open betw een the
switch and the motor. If there is voltage
on the DK BLU wire, backprobe a
jum per ground at the BRN wire at the
motor. If the motor does not run, re
place the motor. If the motor does run,
find the open in the ground circuit.
Note: the ground circuit does run back
through the passenger window DN
contacts and the driver window switch
DN contacts before reaching ground.
Passenger Window
Will Not Work Using
the Passenger Switch.
The Window Will
Work Using the Driver
Switch
1. No power at the passenger switch.
1. Check for voltage on the PNK wire at

the passenger switch. If voltage is not
present, find the open in the circuit be
tween the switch and the I.P. harness
connector.
2. If voltage is present, replace the switch.
Passenger Window
Wont Work Using the
Driver Switch.
2. Switch has internal open.

1. No power.
2. Open in driver switch.
3. Open in harness.
Driver Window Wont

Work. Passenger
Window Works.
1. Switch wont work.
2. Motor has internal open.
3. Motor ground circuit is open.
1. Check driver window action. If the dri

ver w indow works, power is at the
switch.
2. With the driver switch moved to UP,
check for voltage on the DK BLU wire
at the driver switch. If voltage is not
present, replace the switch.
3. W ith voltage present on the DK BLU
wire at the driver switch, find the open
between the driver switch and the pas
senger switch.
1. Switch moved to UP. Check for volt
age at the DK BLU wire at the switch. If
voltage is not present, replace the
switch.
2. Switch moved to UP. Check for volt
age on the DK BLU wire at the motor. If
voltage is present, backprobe a jum per
ground at the BRN wire at the motor. If
the motor wont run, replace the motor.
3. B ackprobe a ju m p e r ground at the
BRN wire at the motor. Move the driver
switch to UP. If the motor runs, find
the open in the ground circuit.
ON-VEHICLE SERVICE
SWITCH REPLACEMENT
POWER WINDOW MOTOR REPLACEMENT
++

2. Door trim panel.
3. Motor. Refer to DOORS (SEC. 10A1).
Install or Connect
1. Motor. R efer to D O O R S (SEC. 10A1).
2. D oor trim panel.
3. B attery ground cable.

2. Door trim panel.
3. Switch connector. The connector is secured with a
retaining nut.
4. Switch. Press in both retaining tabs at the same
time.
- Install or Connect
1.
2.
3.
4.
5.
Switch.
Switch connector.
Retaining nut.
Door trim panel.
WINDSHIELD WIPERRV AND G MODELS

DESCRIPTION
A permanent magnet type wiper is used on RV and G
Series. The motor parts-field magnets, armature, drive
gear etc. are enclosed in a two piece sheet metal housing.
For purposes of explanation the housing halves are
referred to as u pp er and low er housings. The two
housings are attached to each other by ten extrusions
which are staked over. '
The wiper motor is protected by an automatic reset type
c irc u it breaker located on the m otor brush holder
assembly. A fuse located in the fuse block protects the
vehicle wiring.
The wiper motor can be operated only when the ignition
switch is in the run or accessory position.
The wiper motor has three brushes; the com m on, the
low speed, and the high speed. When the ignition switch
is O N , power is applied to the common brush. The low
speed and high speed brushes are connected to their
respective ground via the control switch. When the control
switch is positioned at HI or LO speed, a ground path
is connected to the high or low speed brush in the motor.
The motor runs at the switch selected speed.
In order to have the wiper blades stop in their normal
park position and the w iper motor shut off properly, the
motor must run in LO speed. When the control switch is
moved to the OFF position, the low speed brush circuit
goes through a park switch located in the gear housing
and then to ground at the control switch. The park switch
is normally closed and this allows the wiper to keep
running. When the wiper blades reach their park position,
cam on the gear opens the normally closed park switch,
which turns off the wiper. Refer to Figures 29 and 30.
DIAGNOSIS OF
WINDSHIELD WIPER
Refer to Figures 31 through 35.
ON-VEHICLE SERVICE
WIPER MOTOR REPLACEMENT
RV Truck
4-+ Remove or Disconnect (Figure 36)
1.
2.
3.
W iper motor must be in the Park position.

Ground cable from the battery.
Electrical harness (38) from the w iper motor.
Drive rod (34) from the w iper motor crank arm (36).
Reach down through the access hole (32) in
the plenum and loosen the wiper drive rod
attaching nuts (33) before removing the drive
rod (34).
4. W iper motor to dash panel attaching screws (40).
5. W iper motor.

1. W iper motor.
2. W iper motor to dash panel attaching screws (40).
3. Drive rod (34) the wiper motor crank arm (36).
Lubricate wiper motor crank arm pivot ball (35)
prior to installing the drive rod (34).
4. Electrical harness (38) to the wiper motor.
5. Ground cable to the battery.
G Van
W iper motor must be in Park position.
Ground cable from the battery.
W iper arms.
Cowl panel cover.
Drive arm (34) to the wiper motor crank arm (36).
Loosen nuts (33) holding the drive bar (34) to the
wiper motor crank arm (36) removing the drive bar
(34).
Electrical harness (38) from the w iper motor.
Left dash defroster outlet from the flex hose.
1. G e ar Cam
2. Park S w itc h
(N o rm a lly C lose d)
3. T erm inal No. 5
4. T erm in al No. 4
5. B L K w /d b l LT BLU Tracer
6.
7.
8.
9.
10.
11.
B LK
LT BLU
BLK
M ovable C o n ta c t
O F F P o s itio n
LOW P o s itio n
12. H IG H P o s itio n
13. Pow er
14. Ig n itio n S w itc h
15. Fuse
16. B L K w /d b l Y E L Tracer
17. T erm inal No. 3
Term inal No. 2

Term inal N o. 1
C irc u it B re ake r
C o m m o n B ru sh
22. H igh Speed B ru sh
23. Low Speed B ru sh
F-00668
Figure 29RV Windshield Wiper Diagram

7. Screw securing the left hand heater duct to the
engine cover shroud.
8. Heater duct down and out.
9. Three screws (30) securing the wiper motor to the
cowl.
W iper motor.

1. W iper motor.
2. Three screws (30) securing the w iper motor to the
cowl.
3. Heater duct in and up.
4. Screw securing the left hand heater duct to the

engine cover shroud.
5. Left dash defroster outlet to the flex hose.
6. Electrical harness (38) to the wiper motor.
7. Drive bar (34) to the wiper motor crank arm (36).
Lubricate the wiper motor crank arm pivot ball (35).
8. Cowl panel cover.
9. W iper arms.
10. Ground cable to the battery.
G
17
3.
4.
17.
18.
19.
F.
G.
H.
G ro u n d Park
J u m p e r Park
G ro u n d H igh Speed
G ro u n d Low Speed
P o w e r M o to r
H ig h Speed O p e ra tio n
Low Speed O p e ra tio n
Park O p e ra tio n
F-00792
Figure 30Diagnosis Connection
DIAGNOSIS CHART
PROCEDURE
NO.
SYMPTOM
1) WIPER INOPERATIVEBOTH LOW AND HIGH SPEED
2) LOW SPEED ONLY-INOPERATIVE IN HIGH SPEED
3) HIGH SPEED ONLY-INOPERATIVE IN LOW SPEED
4) ONE SPEED-SAME IN BOTH LOW AND HIGH SPEED
5) BLADES STOP AT RANDOM POSITIONS WHEN WIPER IS TURNED OFF. (DO NOT
RETURN TO PARK POSITION.)
6) WIPER WILL NOT SHUT OFF
7) INTERMITTENT OPERATION
8) WIPER MOTOR RUNS BUT BLADES DONT MOVE
PROCEDURE 1 (W IPER INOPERATIVE)

IGNITION SWITCH ON.' USING A TEST LIGHT CHECK FOR VOLTAGE AT WIPER TERMINAL NO. 19
NO VOLTAGE
GO TO STEP 5
STEP 2
GO TO STEP 2
CHECK FUSE
FUSE BLOWN
...... ... ....................
GO TO STEP 3
FUSE OK
LOCATE AND REPAIR OPEN

IN WIRE FROM FUSE BLOCK
TO WIPER.
F-00715
Figure 31W iper Diagnosis
PROCEDURE 1 (CONT.)
GO TO STEP 4
REPLACE FUSE AND

RECHECK SYSTEM
LOCATE AND REPAIR

SHORTED OR GROUNDED
CONDITION IN WIRING.
PROBLEM IS IN THE
MOTOR. REFER TO
WIPER REPAIR
CHECK THE WIPER SWITCH

GROUND WIRE
CONNECTION. IF OK,
PROBLEM IS IN THE
MOTOR. REFER TO WIPER
REPAIR".
REPLACE THE W IP E R S W IT C H .
PROCEDURE 2 (LO SPEED ONLY) (INOP IN HI)
PROBLEM IS AN
OPEN WIRE FROM
TERMINAL NO. 17
TO THE DASH
SWITCH.
REPAIR THE WIPER

MOTOR. (LOOK FOR A
HIGH SPEED HUNG
BRUSH.)
F-00742
Figure 32Wiper Diagnosis
PROCEDURE 3 ( H I SPEED ONLY) (INOP IN LO)
PROBLEM IS ON OPEN
WIRE FROM WIPER
TERMINAL NO. 2 TO THE
WIPER SWITCH.
REPAIR THE WIPER MOTOR

(LOOK FOR LO SPEED
HUNG BRUSH).
PROCEDURE 4 (ONE S P E E D -S A M E IN BOTH LO AND HI).
PROBLEM IS IN THE WIRING

BETWEEN THE WIPER SWITCH AND
WIPER OR A FAULTY WIPER
SWITCH.
REPAIR THE WIPER MOTOR.

CHECK FOR LO AND HI SPEED
BRUSH LEADS SHORTING
TOGETHER INTERNALLY.
PROCEDURE 5 (W IPER SHUTS OFF BUT BLADES DONT RETURN TO PARK POSITION)
REPLACE THE WIPER PARK

SWITCH ASSY.
WIRE FROM THE WIPER

TERMINAL NO. 3 TO THE
WIPER SWITCH IS OPEN OR
THE SWITCH IS FAULTY.
F-00743
PROCEDURE 6 (W IPER W ILL NOT SHUT OFF)
GO TO STEP 2

(REPLACE THE PARK SWITCH
ASSY.)

(LOOK FOR INTERNAL GRD.
CONDITION IN LO OR
HI BRUSHES)
LOCATE AND REPAIR THE

GROUND CONDITION IN THE
WIRES FROM THE WIPER
TERMINALS 18 OR 17 TO
THE WIPER SWITCH.
PROCEDURE 7 (INTERM ITTENT OPERATION)

(W IPER HAS BOTH SPEEDS)
A WEAK CIRCUIT BREAKER

IS INDICATED. REPLACE
MOTOR END CAP ASSY.
GO TO STEP 2
REPLACE BLADE ELEMENTS
CHECK WIPER LINKAGE FOR

A BINDING CONDITION AND
REPAIR OR REPLACE AS
REQD.
Figure 34Wiper Diagnosis
GO TO STEP 3
PROBLEM IS IN THE WIPER

MOTOR. CHECK FOR
ARMATURE END PLAY,
SHORTED OR GROUNDED
ARMATURE.
F-00744
PROCEDURE 8 (W IPER RUNS BUT BLADES DONT MOVE)
STEP 1
CHECK THE WIPER LINKAGE CONNECTION TO THE WIPER CRANK ARM
LINKAGE CONNECTED
WIPER GEAR IS STRIPPED.
REPLACE THE WIPER MOTOR.
LINKAGE
DISCONNECTED
CHECK THE LINKAGE AND
CHECK THE SYSTEM.
F-00745
Figure 36RV W iper Motor Mounting
Figure 37Van Wiper Motor Mounting
WINDSHIELD W ASH ERRV AND G MODELS

DESCRIPTION
The washer motor is located in the bottom of the
w in d s h ie ld w a sh e r flu id re se rvo ir. The w a sh e r is
controlled by a washer switch, which is located on the
turn signal and m ulti-function lever. Two wires go to the
washer. The white wire is power coming from the fuse
box. The same fuse that protects the washer motor also
protects the wiper motor. The pink wire is the ground
circuit that goes through the washer switch to ground.
Refer to figures 38 and 39.
54
51.
52.
53.
54.
W in d s h ie ld W a sh e r M o to r C o n n e c to r
R e se rvo ir R e ta in in g S cre w
W a sh e r F lu id R e se rvo ir
W in d s h ie ld W a sh e r M o to r
F-00748
Figure 38RV W indshield Washer
50.
51.
52.
53.
54.
Dash Panel
W in d s h ie ld W a s h e r M o to r C o n n e c to r
R e s e rv o ir R e ta in in g S crew
W a sh e r F lu id R e s e rv o ir
W in d s h ie ld W a s h e r M o to r
F-00749
Figure 39Van W indshield Washer
WINDSHIELD WASHER DIAGNOSIS

PROBLEM
Washer Fluid Does
Not Spray on the
Windshield
POSSIBLE CAUSE
1. No fluid.
2. Clogged jets.
3. Clogged filter in the reservoir.
4. Washer motor is not running.
CORRECTION
1. Check the fluid reservoir. Refill, if nec
essary.
2. Using a fine pin, carefully clear the jets.
3. Remove the filter and back flush it.
Also clean the reservoir.
4. Check for power on the WHT wire at
the motor. If there is no power, and the
wipers work, find the open in the power
circuit. If there is power, check the PNK
wire at the washer motor for ground. If
the ground circuit is good, replace the
washer motor.

ON-VEHICLE SERVICE
WASHER MOTOR REPLACEMENT
4. Reservoir.
5. Two reservoir retaining screws.
6. Battery ground cable to the battery.
G Van
RV Models
Battery ground cable from the battery.

Two reservoir retaining screws.
Reservoir.
Electrical connector at the motor.
Fluid tube at the motor.
Motor from the reservoir.

Fluid tubes from the motor.
Motor from the bracket.

Motor to the reservoir.
Fluid tube at the motor.

Motor onto the bracket.
Fluid tubes to the motor.
Electrical connector to the motor.
Battery ground cable to the battery.
WIPER MOTOR UNIT REPAIR

REPLACEMENT OF COMPONENTS
PARK SWITCH
1. Cover
2. Park switch.
Depress tang (61).
I++I Install or Connect (Figure 40)

1. Park switch.
2. Cover.
END CAP-BRUSH HOLDER,

ARMATURE ASSEMBLY
1. Retainer tabs.
2. End cap assembly.
Rotate crank arm clockwise.
3. Armature.

1. Armature in the end cap assembly.
Release the brush spring tension (65).
Slide the brushes back in the brush holders.
Put the armature in the end cap assembly.
Reposition the brush spring legs behind their
respective notches (66).
Tie the armature to the end cap assembly with
small wire.
2. Armature in the w iper housing.
3. End cap into the slot area of the wiper housing.
Remove the wire.

4. End cap assembly into the housing until it bottoms.
5. Retainer tabs.
60.
61.
62.
63.
C o n n e c to r
Tang
C am F o llo w e r
P o in ts
F-00753
Figure 40Park Switch

CRANK ARM, SPACER, SEAL
1. Crank arm retaining nut (71).
Have the crank arm clamped in a vise.
2. Crank arm (70).
3. Shaft seal (72).
4. Spacer (73).

Spacer (73).
Shaftseal (72).
Crank arm (70).
Be sure the wiper motor is in Park.
Install the crank arm according to figure 44 or
45, depending on the vehicle model.
Crank arm retaining nut (71).
70. C ra nk A rm
71. N ut
72. S h a ft Seal
(R ubber)
73. S p a c e r (P la s tic )
74. A rm a tu re End Play
A d ju s tin g S c re w
65. B ru sh S p rin g Leg R eleased

fro m R eta in e r N o tc h
66. R otate B rush S p rin g in D ire c tio n o f A rro w
to R e p o s itio n it B e h in d R e ta in e r N o tc h
67. R e ta in e r N o tc h
F-00754
Figure 41Brush Spring Release Position
F-00755
Figure 43Crank Arm, Spacer and Seal
80. C rank A rm Park P o s itio n C K M o d e ls

81. Id e n tific a tio n C ode
F-00758
Figure 42End Cap Assembly
Figure 44Crank Arm Position RV Models
81. Id e n tific a tio n C od e

82. C rank A rm Park P o s itio n
G Van M o d e ls
F-00759
Figure 45Crank Arm Position Van
WINDSHIELD WIPER DELAY CIRCUIT

DESCRIPTION
The wiper pulse control circuit is an option on RV and G
models. This option allows the wiper to operate at a
slower rate than the low speed setting on the standard
control.
The optional module is inserted into the harness under
the steering column. Refer to figure 46.
DIAGNOSIS OF WIPER
DELAY CIRCUIT
Refer to Figure 47.
ON-VEHICLE SERVICE
REPLACEMENT OF THE MODULE
1. Harness connectors.
2. Module (91) by sliding it off the bracket.
1. Module (91).
2. Harness connectors.
REPLACEMENT OF THE SWITCH.

90. S te e rin g C o lu m n
91. W in d s h ie ld W ip e r D elay M o d u le
92. In s tru m e n t Panel H a rn e ss
Figure 46W iper Pulse Module
F-00818
DIAGNOSIS OF THE WIPER DELAY CIRCUIT
Figure 47Diagnosis of the W iper Delay Module
WINDSHIELD WIPER AND WASHER P MODELS

DESCRIPTION
T h e s y s te m c o n s is ts o f a c o m p o u n d w o u n d
re c ta n g u la r-sh a p e d m oto r a tta ch e d to a g e a r box
containing a parking switch in addition to the gear train.
The gear train consists of a motor arm ature helical
gearshaft which drives an intermediate gear and pinion
assembly. The pinion gear of the intermediate gear and
pinion drives an output gear and shaft assembly.
Turning the wiper switch to the LO speed position
completes the circuits from the wiper term inals 1 and 3 to
ground (Figure 48). Current then flows from the battery via
wiper terminal No. 2 through the series field and divides;
(1) part passes through the armature to ground via wiper
terminal No. 1 to the wiper switch and (2) the second part
passes through the shunt field to ground through wiper

terminal No. 3 to the wiper switch. The wiper switch must
be securely grounded to body metal.
Moving the wiper switch to the HI speed position opens
the shunt field circuit to ground at the switch. However,
the shunt field is connected to a 20 ohm resistor which is
connected across wiper term inals 1 and 3. The shunt field
current then flows via terminal No. 3 through the resistor
to terminal No. 1 to the switch, to ground.
T he p a rk in g c irc u it co vers th a t p o rtio n of w ip e r
operation when the wiper switch is turned o ff and the
wiper blades have not reached the park position.
When the wiper blades are not in the normal park
position, the parking switch contacts are still closed. The
wiper will continue to operate until the wiper output gear
1.
2.
3.
4.
5.
6.
7.
8.
M o to r
S h u n t R e s is to r
S e rie s R e s is to r
G R A W ire
Term inal No. 3
Term inal No. 1
Term inal No. 2
In s tru m e n t Panel S w itc h
9.
10.
11.
12.
13.
14.
15.
16.
M o vin g C o n ta c t
R achet
W a sh er
T erm inal #1
T erm inal #2
S o le n o id
Pawl
O F F P o s itio n
17.
18.
19.
20.
21.
22.
23.
24.
LOW P o s itio n
H IG H P o s itio n
P ow er
RED W ire
PARK S w itc h
R e s is to r
A rm a tu re
B rush
Figure 48P-Model Wiper Diagram

is turned to a position where its cam opens the park
switch. The wiper motor circuits are completed to ground
through the parking switch.
The wiper motor must be securely grounded to body
metal.
The shunt field circuit is completed from terminal No. 3
via the switch to terminal No. 1 through the parking switch
to ground. The series field and armature circuit is also
completed from terminal No. 1 through the parking switch
to ground.
T he s h u n t fie ld is c o n n e c te d d ire c t to g ro u n d ,
by-passing the resistor. This results in LO speed operation
during the parking operation.
When the output gear cam opens the park switch
contacts, the wiper is OFF.
2.
3.
4.
5.
DIAGNOSIS
WIPER SYSTEM CHECKS
1. Inspect for the following items:
a. W iring harness is securely connected to wiper
and switch.
6.
b. W iper motor is securely grounded to body.

c. W ip e r s w itc h is s e c u re ly m o u n te d and
grounded.
d. Check fuse.
If items in Step 1 check out, try operating w iper in
both LO and HI speeds, then turn w iper off
(blades should return to park position). If wiper fails
to operate correctly, proceed to Step 3.
D isconnect w iring harness from w ipe r and try
operating w iper as shown in Figures 49, 50, and 51.
If wiper operates correctly independently of switch
and vehicle w iring, refer to DIAGNOSIS WIPER
ON VEH IC LE.
If wiper still fails to operate correctly in Step 3,
disconnect wiper linkage from motor crank arm and
try operating w iper again. If wiper operates correctly
independently of linkage, check linkage for cause of
wiper m alfunction.
If wiper fails to operate correctly independently of
linkage, remove wiper motor from vehicle and refer
to DIAGNOSIS WIPER OFF VEHICLE.
30.
31.
32.
33.
34.
35.
Term inal No. 2

T erm inal No. 1
T erm in al No. 3
A m m e te r; 0-30 A m p e re Range
G ear S h a ft In T he Park P o s itio n
W ip e r G ro u n d S tra p
F-00808
Figure 49Jum per Connections Low Speed
30.
31.
32.
33.
34.
35.
T erm in al N o. 2
Term in al N o. 1
Term in al N o. 3
A m m e te r; 0-30 A m p e re R ange
G ear S h a ft In T he Park P o s itio n
F-00809
Figure 50Jum per Connections High Speed
30.
31.
32.
33.
34.
35.
T erm in al No. 2
T erm in al No. 1
T erm in al No. 3
A m m e te r; 0-30 A m p e re R ange
G e ar S h a ft In T he Park P o s itio n
F-00810
Figure 51Jum per Connections Off
DIAGNOSIS OF THE WIPERON VEHICLE

PROBLEM
Wiper Not Working or
Intermittent
POSSIBLE CAUSE
1. Blown fuse
2. Open circuit in feed wire (No. 2 terminal
on wiper motor)
3. Loose mounting of wiper switch.
4. Faulty wiper switch.
5. Open circuit in wire to w iper switch (No.
1 term inal on wiper motor)
CORRECTION
1. Locate short circuit and repair. Replace
fuse.
2. Locate broken wire and repair.
3. Tighten switch mounting.
4. Replace switch.
5. Locate broken wire and repair.
Wiper Will Not Shut

Off. Wiper has Both
Lo and Hi
Speeds
Grounded wire (No. 1 term inal on wiper

motor) to wiper switch.
Locate short circuit and repair.
Wiper Will Not Shut

Off. Wiper Has Lo
Speed Only.
1. Defective wiper switch.

2. Grounded wire (No. 3 terminal on wiper
motor) to w iper switch.
1. Replace wiper switch.

2. Locate and repair short circuit.
Wiper Will Not Shut

Off. Wiper has Hi
Speed Only

2. Open circuit in wire (No. 3 term inal on
wiper motor) to wiper switch.

2. Locate and repair broken wire.
Wiper Has Hi
Speed Only
Open circuit in wire (No. 3 term inal on

w iper motor) to wiper switch.
Locate broken wire and repair.
Wiper Has Lo
Speed Only
1. Grounded wire (No. 3 term inal on wiper

motor) to wiper switch.
1. Locate short circuit and repair.
Blades Do Not Return

To Full Park Position
Loose wiper ground strap connection.

Tighten strap connection.
DIAGNOSIS OF THE WIPER OFF VEHICLE

PROBLEM
POSSIBLE CAUSE
Wiper Not Working or

Intermittent
1. Broken or damaged gear train (only if not

working).
2. Poor so ld e r co n n e c tio n s at te rm ina l
board.
3. Loose splice joints at brush plate.
4. Brushes binding in brush holder.
Wiper Will Not

Shut-Off. Wiper Has
Normal Hi and
Lo Speed
CORRECTION
1. Replace gears as required.
2. Resolder wires at terminals.
5. Open circuit in armature.
3. Recrimp or solder splice joints.

4. Clean holder or replace brush, spring
or brush plate assembly.
5. Replace armature.
1. Faulty part switch.

2. Grounded red lead wire.
1. Replace term inal board assembly.

2. Repair short circuit in red wire.
DIAGNOSIS OF THE WIPER OFF VEHICLE (CONT.)

PROBLEM
POSSIBLE CAUSE
CORRECTION
Wiper Will Not Shut

Off. Wiper Has Lo
Speed Only
1. Grounded shunt field coil.

2. Grounded black wire.
1. Replace frame and field assembly.

2. Repair short circuit in black wire.
Wiper Will Not Shut

Off. Wiper Has Hi
Speed Only
1. Open circuit in shunt field coil.

2. Open circuit in black wire.
1. Replace frame and field assembly.

2. Repair broken wire or poor solder con
nection.
Wiper Shuts OffBut

Not In Park Position
Park switch defective or contacts dirty.
Replace term inal board assembly or

clean contacts.
Hi Speed Too Fast
Resistor defective.
Replace term inal board assembly.
DIAGNOSIS OF THE WASHER SYSTEM

PROBLEM
Washers Inoperative
POSSIBLE CAUSE
1 Inadequate quantity of washer solution.
2. Hoses damaged or loose.
3. Plugged screen at end of jar cover hose.

4. Loose electrical connection to washer
pump or wiper switch.
5. Open circuit in feed wire to ratchet relay
coil.
6. W iper switch faulty.
7. Ratchet relay coil defective.
8. Washer nozzles plugged.
9. Ratchet wheel tooth missing.
10. Ratchet pawl spring missing.
11. Faulty pump valve assembly.
Washer Pumps
Continuously When
Wipers Are Operating
1. G rounded wire from ratchet relay to

switch.
2. W iper switch faulty.
3. Ratchet wheel tooth missing.
4. Ratchet wheel dog broken or not con
tacting ratchet wheel teeth.
5. Lock-out tang broken or bent on piston
actuating plate.
CORRECTION
1. Add washer solution.
2. Cut short length off end of hose to in
sure air tig ht connection or replace
hose.
3. Clean screen.
4. Check electrical connections and repair
if necessary.
5. Locate open circuit and repair.
6.
7.
8.
9.
10.
11.
Replace wiper switch.

Replace ratchet relay.
Clean washer nozzles.
Replace ratchet wheel.
Replace ratchet pawl spring.
Replace pump valve assembly.
1. Locate grounded wire and repair.

3. Replace ratchet wheel.
4. Replace of repair ratchet wheel dog.
5. Replace piston actuating plate.

ON-VEHICLE SERVICE
WIPER MOTOR
W iper motor replacement procedures are not included
here since installation is performed by the individual body
manufacturers; however, disassem bly of the unit will be
covered in Unit Repair.
UNIT REPAIR
WIPER MOTOR DISASSEMBLY

GEAR BOX AND MOTOR
Remove or Disconnect (Figure 52, 53, and 54)
1. Two washer pump mounting screws (72).
2. Pump (71) from the gear box cover.
3. Washer pump drive cam (75).
Wedge off the cam and the plate using two
screwdrivers.
Clamp the crank arm (57) in a vise before
removing the nut (58).
5. Crank arm (57).
6. Seal cap (56).
8. Spacer (54).
9. Gear box cover retaining rivets.
Drill out the rivets.
10. Gear box cover (53).
11. O utput gear and shaft assembly (52).
12. Intermediate gear and pinion assembly off the shaft
(51).
13. T erm inal board and p a rk sw itch assem bly, if
necessary.
Unsolder the motor leads from the terminals.
Label the motor leads.

Drill out the rivets securing the terminal board
and the park sw itch ground strap to the
m ounting plate.
14. Motor through bolts (42).
15. Motor from the mounting plate.
Tap motor frame lightly.
16. Brush spring tension (61).
17. Armature (46) and end plate (43) from the motor
frame (44).
18. End plate (43) from the armature (46).
There is a th ru s t plug (45) betw een the
armature shaft and the end plate.
19. End play adjusting washers (47 and 41) from the
armature.
Note the washers positions.
INSPECTION
Inspect all the parts for wear or damage. All the parts
can be replaced individually except the motor frame and
field, which is serviced as an assembly. Service kits
provide screws, nuts and washers to replace the gear
cover and terminal board rivets.
40.
41.
42.
43.
44.
45.
46.
47.
B ru s h e s
Wave W a sh e rs
M o to r T h ro u g h B o lt
End P late
F ram e A n d F ie ld
T h ru s t P lug
A rm a tu re
F la t W a sh e rs
47.
48.
49.
50.
51.
F lat W ashers
B rush P late A s s e m b ly A n d M o u n tin g B ra cke ts
G ear B ox H o u s in g
W ave W a sh e r
In te rm e d ia te G ear
O u tp u t G ear A n d S h a ft A s s e m b ly
G ear B ox C over
S p a ce r
Seal Cap
57.
58.
59.
60.
61.
C ra nk A rm
N ut
B ru s h H o ld e r
S lo t
G roo ve F o r B ru sh S p rin g
F-00811
Figure 54M otor Assem bly
WIPER MOTOR ASSEMBLY

GEAR BOX AND MOTOR
Install or Connect (Figure 52, 53, 54, and 55)
1. End play adjusting washers (41 and 47) on the
armature (46).
2. End plate (43) on the armature (46).
Make sure the thrust plug (45) is between the
armature shaft and the endplate.
Lubricate the bearing with light machine oil.
3. Armature and the end plate assembly on the motor
frame (44).
4. Brush spring tension (60).
5. Motor to the m ounting plate (49).
6. Motor through bolts (42).
7. Term inal board and p ark sw itch assem bly, if
removed.
Secure the term inal board and park switch
with the screws, washers and nuts supplied in
the rebuild kits.
Solder the motor leads to the terminals.
8. Intermediate gear and pinion assembly on the shaft
(51).
Lubricate the gear teeth with Delco Cam and
Ball Bearing Grease (or equivalent).
9. Output gear and shaft assembly (52).
10. Gear box cover (53).
11. Gear box cover screw, washers, and nuts.
12. Spacer (54).
80
57. C ra nk A rm
80. G ear C ase A lig n m e n t M a rks
81. C ra nk A rm A lig n m e n t M arks
Figure 55Park Alignm ent
F-00834
ftfi
85.
86.
87.
88.
89.
90.
91.
92.
on
Valve A s s e m b ly M o u n tin g S crew

Pum p
R achet D og
R achet D og R e ta in in g S crew
S o le n o id C oil
S o le n o id P lu n g e r
R achet W h e el
93.
94.
95.
96.
97.
98.
99.
100.
R achet Pawl S p rin g

Cam F o llo w e r U p p e r Pin
E R ing
Cam F o llo w e r
Fram e
R achet Pawl
R achet W h e el S p rin g
R e ta in in g G roove
F-00835
Figure 56Washer Pump Assembly

14. Seal cap (56).
15. Crank arm (57).
Place the w iper in the park position.
Install the crank arm on the output shaft.
Rotate the crank so that the alignm ent marks
line up with those on the cover (80 and 81).
C la m p th e c ra n k arm in a v is e b e fo re
tightening the retaining nut.
17. Washer pump drive cam (75).
Press the cam on the shaft.
18. Pump on the gear box cover.
19. Two pump mounting screws (72).
WINDSHIELD WASHER
DISASSEMBLY
1. Washer pump cover
2. Ratchet dog retaining screw (89).
3. Solenoid assem bly (90) and ratchet dog (88) off the
pump frame (97).
Hold the spring loaded solenoid plunger (91)
in position while lifting the solenoid assembly.
4. Ratchet pawl spring (93).
5. Ratchet pawl retaining ring (94).
6. Ratchet pawl (98) from the cam follower Upper Pin.
7. Ratchet wheel spring (99) out of the shaft groove.
8. Ratchet wheel (92) from the shaft.
9. Pump and actuator plate assembly.
Pull the pump housing away from the drive
cam until the housing grooves (100) clear the
frame.
Lift the cam follower (96) from the ratchet
wheel and cam follower shafts.
10. Four valve assem bly screws (85).
11. Valve assembly (86) from the pump housing.

WINDSHIELD WASHER ASSEMBLY
|~n~| Install or Connect (Figure 56)
1. Valve assembly (86). To the pump housing (87).
Be sure th a t the seal between the pum p
h o u sin g and th e valve p la te is p ro p e rly
positioned in the pump housing and valve
plate grooves.
Be sure that the triple seal is properly installed
b e tw e e n th e v a lv e b o d y a nd th e p ip e
assembly.
2. Four valve assem bly screws (85).
3. Pump (87) and cam follower (96) assembly to the
frame (97).
4. Ratchet wheel (92) to the shaft.

5. Ratchet wheel spring (99) into the shaft groove.
6. Ratchet pawl (98) onto the cam follower upper pin
(94).
7. Ratchet pawl retaining E ring (95).
8. Ratchet pawl spring (93).
9. Solenoid assembly (90) and ratchet dog (88) on the
pump fram e (97).
Hold the spring loaded solenoid plunger (91)
in p o s itio n w h ile in s ta llin g th e so le n o id
assembly.
10. Ratchet dog retaining screw (89).
11. Washer pump cover.
HEATER SYSTEM CIRCUITS

DESCRIPTION
The heater blower motor is controlled by the blower
switch. The blower switch is a four position switch; off,
low, medium, and high. This switch controls the speed of
the blower motor by connecting different resistances into
the motor circuit, thereby dropping the voltage available to
the motor.
The blower switch is located on the control assembly.
The harness from the switch goes to the dash panel
connector and into the engine compartment. The harness
is then routed to the resistor block, which is located on the
blower housing. From the resistor block, the harness then
g o e s to th e b lo w e r m otor. T h e w ire c o lo rs
can be found in the wiring diagrams which are at the back

of this manual.
DIAGNOSIS
For diagnosis of the heater blower circuit, refer to
HEATING AND VENTILATION (SEC. 1A).
ON-VEHICLE SERVICE
For on-vehicle service of the heater blower circuit, refer
to HEATING AND VENTILATION (SEC. 1A).
AIR CONDITIONING ELECTRICAL SYSTEM

DESCRIPTION
DIAGNOSIS
The compressor electro-magnetic clutch is turned on

and off by the pressure sensing switch. When refrigerant
pressure drops below a certain predetermined level, the
switch opens the compressor clutch circuit, which causes
the refrigeration system to stop working. The pressure
sensing switch is located near the top of the accumulator.
For diagnosis of the A/C electrical system, refer to AIR

ON-VEHICLE SERVICE
For on-vehicle service of the air conditioning, refer to
SPECIAL TOOLS
CHASSIS ELECTRICAL 8B-1
SECTION 8B
CHASSIS ELECTRICAL
CONTENTS
SUBJECT
PAGE
Front Lighting S y s te m ................................................................................................................................................ 8B- 1

Headlamp S y s te m .................................................................................................................................................... 8B- 1
Diagnosis Of Headlamp................................................................................................................................................ 8B- 6
On-Vehicle S e rv ic e .................................................................................................................................................. 8B- 7
Front Parking Lamps S ystem ..................................................................................................................................8B- 8
Diagnosis Of The Front Parking L a m p s ...... .............................................................................................................8B- 8
On-Vehicle S e rv ic e .................................................................................................................................................. 8B- 9
Front Side Marker Lamp S y s te m ............................................................................................................................8B-10
Diagnosis Of The Front Side Marker Lamps............................................................................................................. 8B-10
On-Vehicle S e rv ic e .................................................................................................................................................. 8B-11
Rear Lighting S ystem s................................................................................................................................................ 8B-11
Rear Running Lamps And Marker L a m p s ............................................................................................................. 8B-11
Rear Park L am ps.......................................................................................................................................................8B-11
Rear Turn, Stop And Hazard System s................................................................................................................... 8B-11
Back-Up Lamp S y s te m ............................................................................................................................................ 8B-12
Rear Lamp Harness Layouts....................................................................................................................................8B-12
Diagnosis Of The Rear Side Marker L a m p s ............................................................................................................. 8B-17
Diagnosis Of The Running, Park And License Lamps.............................................................................................8B-18
Diagnosis Of The Turn Signal And Hazard S ystem s............................................................................................... 8B-19
Diagnosis Of The Stoplamp S y s te m ..........................................................................................................................8B-20
Diagnosis Of The Back Up Lamp S ystem ................................................................................................................. 8B-20
On-Vehicle S e rv ic e .................................................................................................................................................. 8B-21
Fuses, Circuit Breakers S pecifications..................................................................................................................... 8B-27
Lamp S pecifications.................................................................................................................................................... 8B-29
FRONT LIGHT SYSTEMS

The front lighting system includes the headlamps, the
front parking lamps, and the front side marker lamps. The
circuit starts at the fuse block and goes to the light switch
in the instrum ent panel. From the light switch the circuit
goes to the dash panel connector and then to the front
lamps.
HEADLAMP SYSTEM
The headlamp system has two options. One option is
two headlamps, each headlamp having a parking lamp
located under it. The other option is four headlamps, with
the parking lam ps located in the g rill. On the four
headlamp option, when the low beam circuit is energized,
only the upper headlamps will be on. When the high
beam circuit is energized, only the lower headlamps will
be on. Refer to figures 1, 2, 3, and 4.
8B-2 CHASSIS ELECTRICAL
Figure 1RV Two Headlamp Wiring Harness
Figure 2RV Four Headlamp Wiring Harness
41.
42.
43.
45.
46.
H e a d la m p
G ro u n d
Two H e a d la m p H a rn e ss
Dash Panel C o n n e c to r
F o u r H e a d la m p H a rn e s s
47. L ow er H e a d la m p
Figure 3G Van Front Lighting Harness
F-00862
Figure 4Two Headlamp Assembly
DIAGNOSIS OF HEADLAMP
PROBLEM
One Headlamp
Inoperative Or
Intermittent.
POSSIBLE CAUSE
1. Loose connection.
2. Defective sealed beam unit.
One Or More
Headlamps Are Dim.
One Or More
Headlamps Short
Life.
All Headlamps
Inoperative Or
Intermittent.
1. O p e n g ro u n d c o n n e c tio n at th e
headlamp.
2. Black ground w ire m islocated in the
headlam p connector (three-wire, hi-lo,
connector only).
Charge circuit problem.
1. Loosen connection.
2. Defective dim m er switch.
3. Open wiring lamp switch to the dim m er

switch.
4. Open w iring lamp switch to the battery.
5. Shorted ground circuit.
6. Defective switch.
Upper Or Lower Beam

Will Not Light Or
Intermittent.
1. Open connection or defective dim m er

switch.
2. Short circuit to ground.
CORRECTION
1. S e c u re th e c o n n e c tio n s to th e
headlamp including the ground (black
wire).
2. Replace the headlamp.
1. Repair the black wire connection be
tween headlamp and the body ground.
2. Relocate the black wire in the connec
tor.
Refer to ENGINE ELECTRICAL (SEC.

6D), charging system diagnosis.
1. Check and secure the connections at

the dim m er switch and the lamp switch.
2. Check the voltage at the dim m er switch
with a test lamp. Refer to CAB ELEC
TRICAL (SEC. 8A) for the test points.
3. Check the yellow wire with a test lamp.
If the bulb lamps at the lamp switch yel
low wire terminal but not at the dim m er
switch, repair the open wire.
4. Check the red wire term inal at the lamp
switch with a test lamp. If the bulb does
not lamp, repair the open red wire cir
cuit to the battery (possible open fusi
ble link).
5. If, after a few minutes operation, the
headlamps flicker O N and OFF
and/or a thum ping noise can be heard
from the lamp switch (circuit breaker
opening and closing), repair the short
to ground in the circuit between the
lamp switch and the headlamps. After
repairing the short, check for headlamp
flickering after one minute operation. If
flickering occurs, the circu it breaker
has been d a m a g e d and the lam p
switch must be replaced.
6. Check the red and yellow wire term i
nals at the lamp switch with test. If the
bulb lamps at the red wire terminal but
not at the yellow term inal, replace the
lamp switch.
1. Check the dim m er switch term inals
with a test lamp. If the bulb lights at the
light green or tan wire terminals, repair
the open wiring between the dim m er
switch and the headlamps. If the bulb
will not light at either of these term i
nals, depending upon switch position,
replace the dim m er switch.
2. F o llo w th e d ia g n o s is a b o v e (a ll
headlamps inoperative or intermittent).
F-00751
Figure 5Four Headlamp Assembly
ON-VEHICLE SERVICE
HEADLAMP UNIT REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Headlamp bezel retaining screws.
Bezel.
Retaining ring screws. Be careful not to move the
adjustm ent screws.
Retaining ring spring, using a hooked tool.
Retaining ring from the m ounting ring.
Headlamp unit.
Headlamp electrical connector.
|++-| Install or Connect (Figure 4 and 5)

1. Headlamp electrical connector.
On the dual headlamp option, the 2A1 headlamp
is the upper unit and the 1A1 headlamp is the
lower unit.
2. Headlamp.
3. Retaining ring.
4. Retaining ring screws. Make sure that the headlamp is

properly seated.
5.
6.
7.
8.
Retaining ring spring.

Bezel.
Bezel retaining screws.
Battery ground cable to the battery.
HEADLAMP ADJUSTMENT (Figure 6)

Horizontal and vertical aiming of each headlam p is
done by two (2) a d ju s tin g screw s w hich m ove the
mounting ring against the tension of the coil spring.
S om e s ta te and lo c a l a u th o ritie s have s p e c ific
re q u ire m e n ts fo r a im in g h e a d la m p s a nd th e s e
requirements should be followed.
Replacement of a headlamp will normally not require
aiming adjustment. However, do check the aim.
U se th e s a fe ty a im e r J-6878-01 or e q u iv a le n t.
Instructions for using the safety aimer are supplied by the
instrument manufacturer.
DIMMER SWITCH REPLACEMENT

Refer to STEERING COLUM NS (SEC. 3B4).

LAMP SWITCH REPLACEMENT
Refer to Rear Lighting Systems.
_
FRONT PARKING LAMPS SYSTEM
N>
The front parking lamps circuit is in the headlamp

harness. The circuit starts from the fuse block, goes to the
lamp switch, and then forward to the front parking lamps.
The circuit also includes the rear parking lamps, which
are covered later in this section. The parking lamp system
is turned on when the lamp switch is pulled out to the first
detent.
DESCRIPTION
20. V e rtic a l A d ju s tin g S cre w

21. H o riz o n ta l A d ju s tin g S cre w
F-00821
Figure 6Headlamp Aiming Screws
DIAGNOSIS OF THE FRONT PARKING LAMPS

PROBLEM
POSSIBLE CAUSE
CORRECTION
One Side Not

Working.
1. Bulb burnt out.

2. Open connection at the bulb socket or
the ground wire terminal.

2. Jum per the bulb base socket connec
tion to ground. If the bulb lamps, repair
the open ground circuit.
Both Sides Not

Working.
1. Fuse blown.
1. R eplace the fu se. If the new fuse

blows, repair the short to ground in the
brown wire circuit between the fuse
panel through the lamp switch to the
lamps.
2. Secure the c o n n e cto r at the lam p
switch.
3. Using a test lamp, check the circuit on
both sides of the fuse. If the test bulb
does not lamp on either side, repair the
open circuit between the fuse panel
and the battery (possible open fusible
link). If the test bulb lamps at the lamp
switch brown wire term inal, repair the
open wiring between the lamp switch
and the lamps.
4. If the test bulb lam ps at the lamp
socket brown wire term inal, replace the
bulb(s).
5. If the test bulb lam ps at the lamp switch
orange wire but not at the brown wire,
replace the defective lamp switch.
3. Open wiring.
4. M ultiple bulb burnout.
5. Defective lamp switch.
25. Park Lam p

26. N u t
27. R a d ia to r G rille
B-00824
Figure 7Parking Lamp Assembly
ON-VEHICLE SERVICE
REPLACEMENT OF THE LAMP SWITCH
Refer to INSTRUMENT PANEL (SEC. 8C).
REPLACEMENT OF THE FRONT PARKING LAMP

RV and G ModelsTwo Headlamp Option
|<-+| Remove or Disconnect (Figures 3 and 4)
1.
2.
3.
4.
5.
6.

Four bezel retaining screws.
Bezel.
Three park lamp retaining screws.
Parking lamp.
Electrical connector from the parking lamp.
5. Four bezel retaining screws.

RV and G ModelsFour Headlamp Option
++
1. Radiator grille (27). Refer to SHEET METAL (SEC.

2B).
2. Electrical connector from the parking lamp.
3. Two nuts (26) at the top of the housing (25).
4. Housing by lifting it up from the radiator grille.

1. Park lamp housing (25) on the radiator grille (27).

1.
2.
3.
4.
Electrical connector to the parking lamp.

Parking lamp.
Three parking lamp retaining screws.
Bezel.
2. Two nuts (26) at the top of the housing (25).

3. Electrical connector into the parking lamp.
4. Radiator grille (27). Refer to SHEET METAL (SEC.
2B).

FRONT SIDE MARKER LAMP
SYSTEM
DESCRIPTION
The front side marker lamp circuit is included in the
headlamp harness. The circuit starts at the lamp switch. It
goes to the dash panel connector and out to the front side
marker lamps. The circuit also branches at the lamp
switch and goes to the rear side marker lamps. This part
of the circuit is covered later in this section.
DIAGNOSIS OF THE FRONT SIDE MARKER LAMPS

PROBLEM
One Lamp Wont
Work
POSSIBLE CAUSE
1. Turn signal bulb burnt out (front lamp).
2. Side marker bulb burnt out.

3. Loose connection or open in wiring.
Front or Rear Lamps

Wont Work
1. Loose connection or open ground circuit.
2. Multiple bulbs burnt out.
All Lamps Wont Work
1. Blown fuse.
3. Open in wiring.
CORRECTION
1. Switch turn signals on. If the signal
bulb does not light, replace the bulb.
(Bulb filam ent provides ground path for
marker lamp bulb hrough the dark blue
or brown wires.)
3. Using a test lamp, check the brown
wire terminal at the bulb socket. If the
test bulb lights, repair the open ground
circuit. If the bulb does not light, repair
the open in the brown wire circuit.
1. If the associated tail or park lamps do
not operate, check all the connectors in
the brown wire circuit. If the park and
turn lamps are not working, repair the
open ground connections.
2. Replace the burnt out bulbs.
1. If the park and tail lamps do not oper

ate, replace the blown fuse. If the new
fuse blows, check for a short to ground
between the fuse panel and the lamps.
2. Secure the c o n n e c to r to the lam p
switch.
3. Check the tail lamp fuse with a test
lamp. If the test bulb lights, repair the
open wiring between the fuse and the
light switch. If not, repair the open w ir
ing between the fuse and the battery.
(Possible open fusible link.)
4. Check the lamp switch with a test light.
If the test bulb lights at the orange wire
but not at the brown wire, replace the
lamp switch.
30.
31.
32.
34.
F ro n t F e n d e r
S id e M arker Lam p
S crew
N ut
F-00871
Figure 9G Van Front Side Marker Lamp
ON-VEHICLE SERVICE
REPLACEMENT OF THE FRONT SIDE
MARKER LAMP

1. Bulb (33) the lamp (31).
2. Side marker lamp (31) into the fender (30).
3. Two screws (32).

1. Two screws (32).
2. Side marker lamp (31).
3. Bulb (33) from the lamp (31).
REAR LIGHTING SYSTEMS

The rear lighting systems contain the circuits for the
running, park, turn, stop and license lamps. One bulb
may function for more than one circuit. The harness for
the rear lighting systems starts at the fuse block, goes to
the various switches and then back along the left frame to
the various lamps.
REAR RUNNING LAMPS AND

MARKER LAMPS
This circuit starts at the lamp switch. The lamps will be
on when the lamp switch is in the first and second
detents. The front park lamps and front marker lamps will
also be on when the lamp switch is in the first detent.
REAR PARK LAMPS

These lamps will be on when the lamp switch is in the
first detent. The front park lamps will also be on. The side
marker lamps will also be on.
REAR TURN, STOP, AND

HAZARD SYSTEMS
These three systems use the same bulb in the rear
lamps. When the rear turn system is turned on, a thermal
oscillator is turned on, which causes the system to flash.
The front park lamps are also a part of the turn system.
The stop lamp system is turned on by a brake switch
closing. The two rear bright lamps are then turned on.
The hazard system is turned on by the hazard switch.
The hazard system therm al oscillator is then turned on
1.
2.
3.
4.
Ig n itio n S w itc h C o n n e c to r
N e u tra l S w itc h C o n n e c to r
D im m e r S w itc h C o n n e c to r
B ack Up S w itc h C o n n e c to r
5.
6.
7.
8.
S te e rin g C o lu m n
Turn S ig n a l In d ic a to r C o n n e c to r
S to p Lam p S w itc h C o n n e c to r W ith C ru is e C o n tro l
S to p Lam p S w itc h C o n n e c to r W ith o u t C ru is e C o n tro l
Figure 10Steering Column Connectors RV Models

which causes the front park lamps and the rear bright
lamps to flash.
BACKUP LAMP SYSTEM

This
shifted
turning
located
circuit is turned on when the transm ission is

into reverse. The backup switch is closed, thus
on the backup lamps. The backup lamps are
in the rear lamp assemblies.
REAR LAMP HARNESS LAYOUTS

Refer to Figures 10, 11, 12, 13, 14, 15,16, 17, 18 and 19.
F-00837
10.
11.
12.
13.
14.
15.
16.
M arker Lam p (Cream )

R u n n in g , Turn, S to p Lam p (Gray)
G rou nd
L e ft H a rn e ss C o n n e c to r
R ig h t H a rn e s s C o n n e c to r
L ic e n s e Lam p
B ack Up Lam p
F-00838
Figure 12Rear Lamp Harness Suburban
10.
11.
12.
15.
16.
M arker L am p (Cream )
R u n n in g , Turn, S to p Lam p (Gray)
G ro u n d
L ic e n s e Lam p
B ack Up Lam p
F-00841
Figure 13Rear Lamp Harness Fleetside
13. L e ft H a rn e ss C o n n e c to r
15. L ic e n s e Lam p
F-00842
Figure 14Rear Lamp Harness Stepside
Figure 15Rear Lamp Harness Utility Vehicle
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
R ear L ig h tin g H a rn e ss C o n n e c to r
R ear Lam p A s s e m b lie s
R un, S top, Turn Lam p C o n n e c to r
B a ck Up Lam p C o n n e c to r
L ic e n s e Lam p C o n n e c to r
F uel Tank S e nd e r C o n n e c to r
S id e M arker Lam p C o n n e c to r
G ro u n d
Run, Stop, Turn, B a ck Up
L a m p s C o n n e c to r
LT GRN W ire
G R N W ire
BRN W ire
L ic e n s e Lamp, F uel Tank
S e n d e r C o n n e c to r
63. W H W ire
64. ORG W ire
65. P N K W ire
66. BRN W ire
67. R ear Lam p H arne ss
68 . Y E L W ire
69. DK G RN W ire
70. LT GRN W ire
71. In s tru m e n t Panel H a rne ss
F-00872
Figure 16Rear Lamp Harness Van
Figure 18Tailgate Lamp Wiring Harness
30. In s tru m e n t Panel H a rn e ss C o n n e c to r

31. C o n n e c to r 4 S peed M an ua l T ra n s m is s io n
32. A u to m a tic T ra n s m is s io n
33. Back Up S w itc h

34. M anual T ra n s m is s io n
Figure 19RV Model Backup Lamp Switch and Wiring
DIAGNOSIS OF THE REAR SIDE MARKER LAMPS

PROBLEM
One Lamp Wont
Work
POSSIBLE CAUSE
1. Turn signal bulb burnt out (front lamp).
2. Side marker bulb burnt out.

3. Loose connection or open in wiring.
Front Or Rear Lamps

Wont Work
1. Loose connection or open ground circuit.
2. Multiple bulbs burnt out.
CORRECTION
1. Switch turn signals on. If the signal
bulb does not light, replace the bulb.
(Bulb filam ent provides ground path for
m arker lamp bulb through the dark
blue or brown wires.)
3. Using a test lamp, check the brown
wire term inal at the bulb socket. If the
test bulb lights, repair the open ground
circuit. If the bulb does not light, repair
the open in the brown wire circuit.
1. If the associated tail or park lamps do
not operate, check all the connectors in
the brown wire circuit. If the park and
turn lamps are not working, repair the
open ground connections.
2. Replace the burnt out bulbs.
DIAGNOSIS OF THE REAR SIDE MARKER LAMPS (CONT.)

PROBLEM
POSSIBLE CAUSE
All Lamps Wont Work
1. Blown fuse.
3. Open in wiring.
CORRECTION
1. If the park and tail lamps do not oper
ate, replace the blown fuse. If the new
fuse blows, check for a short to ground
between the fuse panel and the lamps.
2. Secure the c o n n e c to r to th e lam p
switch.
3. C heck the tailla m p fuse with a test
lamp. If the test bulb lights, repair the
open wiring between the fuse and the
lamp switch. If not, repair the open w ir
ing between the fuse and the battery.
(Possible open fusible link.)
4. Check the lamp switch with a test lamp.
If the test bulb lights at the orange wire
but not at the brown wire, replace the
light switch.
DIAGNOSIS OF THE RUNNING, PARK

AND LICENSE LAMPS
PROBLEM
POSSIBLE CAUSE
CORRECTION
One Side Not Working
1. Bulb burnt out.

2. Open connection at the bulb socket or
the ground wire terminal.

2. Jum per the bulb base socket connec
tion to ground. If the bulb lights, repair
the open ground circuit.
Both Sides Not

Working
1. Tail lamp fuse blown.

brown wire circuit between the fuse
panel through the lamp switch to the
lamp.
2. Secure the c o n n e c to r at the lam p
switch.
3. Using a test lamp, check a circuit on
both sides of the fuse. If the test bulb
does not light on either side, repair the
open circuit between the fuse panel
and the battery (possible open fusible
link). If the test bulb lights at the lamp
switch brown wire term inal, repair the
open wiring between the lamp switch
and the lamps.
4. If the test bulb lights at the lamp socket
b ro w n w ire te rm in a l, re p la c e th e
bulb(s).'
5. If the test bulb lights at the lamp switch
orange wire but not at the brown wire,
replace the defective lamp switch.
3. Open wiring.
4. M ultiple bulb burnout.
DIAGNOSIS OF THE TURN SIGNAL AND

HAZARD SYSTEMS
PROBLEM
POSSIBLE CAUSE
CORRECTION
Turn Signals Not

Working On One Side
1. Bulb(s) burnt out (flasher cannot be

heard).
1. Turn the hazard warning system O N .

If one or more bulbs are inoperative, re
place the bulbs as necessary.
2. Turn the hazard warning system on. If
one or more bulbs are inoperative, use
the test lamp and check the circuit at
the bulb socket. If the test bulb lights,
repair the open ground connection. If
not, repair the open wiring between the
bulb socket and the turn signal switch.
all the front lamps and rear lamps oper
ate, check for an improper bulb (see
bulb chart). If the bulbs are OK, replace
the defective turn signal switch.
4. Locate and repair the short to ground
by disconnecting the front and rear cir
cuits separately.
2. Open wiring or loose ground connector.
3. Improper bulb or defective turn signal

switch.
4. Short to ground. (Flasher can be heard,

no bulbs operate).
Turn Signals Not

Working
1. Blown turn signal fuse.
2. Defective flasher (located in conven

ience center near steering column).
Hazard Warning Not

Working
1. Blown stop-hazard fuse.
2. Faulty hazard warning flasher. (Located

in the convenience center).
3. Open in the wiring or a defective turn

signal switch.

all the lam ps operate, replace the
blown fuse. If the new fuse blows, re
pair the short to ground between the
fuse and the lamps.
2. If the turn signal fuse is OK and the
hazard warning system will operate the
lamps, replace the defective turn signal
flasher.
3. Secure the steering column connector.
1. Switch the turn signals O N . If the
lights operate, replace the stop-hazard
fuse if blown. If the new fuse blows, re
pair the short to ground. (Could be in
stop lamp circuit).
2. If the stop-hazard fuse is OK, switch
the turn signals on. If the lamps oper
ate, re p la c e th e d e fe c tiv e h aza rd
flasher.
3. Using the test lamp, check the brown
wire in the turn signal steering column
connector. If the test bulb does not
light, repair the open circuit between
the flasher and the connector. If the test
lamp indicates power on the brown wire
and connection is good, use a test
lamp to check the output term inals (It.
blue, blue, ye llo w and d a rk green
wires).
DIAGNOSIS OF THE STOPLAMP SYSTEM

PROBLEM
One Bulb Not Working
One Side Not Working
(Multi-Bulb Design)
POSSIBLE CAUSE
Bulb burnt out.
1. Loose connection, open wiring or faulty
bulbs.
2. Faulty directional signal switch or can

celling cam.
All Stoplamps
Inoperative
1. Stop-hazard fuse is blown.
2. Open in the wire from the fuse to the

stop-switch.
3. Stop-switch misadjusted or faulty.
Will Not Turn Off
Stop switch misadjusted or faulty.
CORRECTION
Replace the bulb.
1. Turn on the directional signal. If lamp
does not operate, check the bulbs. If
the bulbs are OK, check all connec
tions. If the lam p still does not operate,
use the test lamp and check for open
wiring.
2. If the lamp will operate by turning the
directional signal on, the switch is not
centering properly during the cancel
ling operation. Replace faulty cancel
ling cam or directional signal switch.
circuit between the fuse and the lamps.
2. Check for power at the brown wire at
the stop-switch and at the fuse. If there
is power at the fuse but not at the
switch, check for an open in the brown
wire.
3. With the brake pedal pressed, check
the white wire term inal in the steering
column connector with a test lamp. If
the bulb does not light, check the stop
switch for proper adjustment. If the ad
justm ent is OK, jum per the stop switch.
If the stop lamps operate, replace the
stop switch.
Readjust the switch. If the switch still
malfunctions, replace the switch.
DIAGNOSIS OF THE BACKUP LAMP SYSTEM

PROBLEM
POSSIBLE CAUSE
CORRECTION
One Lamp Not

Working Or
Intermittent
1. Loose or burnt out bulb.

3. Open ground connections.
1. Secure or replace the bulb.

2. Tighten the connectors.
3. Repair the bulb ground circuit.
Both Lamps Not

Working Or
Intermittent
1. G ear se le cto r sw itch is m isadjusted

(open when shifter lever is in reverse po
sition).
2. Loose connection or open circuit.
1. Readjust the gear selector switch.
3. Blown fuse.
2. Check all connectors. If OK, check the

continuity of the circu it from the fuse to
the lamp on either side of the fuse. Cor
rect the open circuit from the battery to
the fuse.
circuit from the fuse through the gear
selector or from the fuse through the
g ea r s e le c to r o r the b a cku p lam p
switch to the backup lamps.
DIAGNOSIS OF THE BACKUP LAMP SYSTEM (CONT.)

PROBLEM
Both Lamps Not
Working Or
Intermittent
(Continued)
POSSIBLE CAUSE
CORRECTION
4. Faulty gear selector or backup lamp

switch.
4. W ith the ignition O N , check the

switch term inals in the backup position
with the test lamp. If the test bulb lights
at the dark blue wire terminal but not at
the light green wire terminal, replace
the switch.
5. If the test bulb lights at the ignition
switch battery terminal, but not at the
output term inal, replace the ignition
switch.
5. Faulty ignition switch.
Lamp Will Not Turn

Off
Gear selector switch misadjusted (closed

when the shift lever is not in the reverse
position).
Readjust the gear selector switch.
Figure 20RV Model Rear Lamp Assembly
ON-VEHICLE SERVICE
REAR LAMP BULB REPLACEMENTRV MODELS
|<~~[ Remove or Disconnect (Figure 20)
2. Lens retaining screws (86).
3. Lens (80).
4. Bulb (10, 11 or 16).

1. Bulb (10, 11 or 16).
2. Lens (80).
3. Lens retaining screws (86).

REAR LAMP HOUSING AND
SEAL REPLACEMENT-RV MODELS
3 . H o u s in g (1 1 2 ).
4 . B u lb s o c k e t (5 6 ).
Remove or Disconnect (Figures 20)

B a tte r y g r o u n d c a b le fr o m
5 . B u lb .
Install or Connect
th e b a tte ry .
L e n s r e ta in in g s c r e w s (8 6 ).
1 . B u lb .
L e n s (8 0 ).
H o u s in g r e ta in in g s c r e w s (8 1 ).
H o u s in g (8 2 ).
L a m p s (1 0 , 11 a n d 1 6 ).
S e a l (8 4 ).
2.
B u lb s o c k e t ( 5 6 ) in to t h e h o u s in g (1 1 2 ).
3.
H o u s in g (1 1 2 ).
4.
H o u s in g r e ta in in g s c r e w s (1 1 3 ).
5.
B a tte r y g r o u n d c a b le fr o m
th e b a tte ry .
LIGHT SWITCH REPLACEMENT
1. S e a l ( 8 4 ) .
In s ta ll t h e s e a l w ith t h e ta b s (8 3 ) p o in te d fo r w a r d .
A p p l y a d h e s i v e a t t h e f o u r c o r n e r s o f t h e s e a l in
o r d e r t o h o ld t h e s e a l in p la c e .
L a m p s (1 0 , 11 a n d 1 6 ).
RV Models
K-M Remove or Disconnect (Figures 24 and 25)
1. B a tte r y g r o u n d c a b le fr o m
2.
H o u s in g (8 2 ).
th e b a tte ry .
K n o b a s s e m b ly (1 3 1 ).
H o u s in g s c r e w s (8 1 ).
L e n s (8 0 ).
P u s h in r e t a in e r p in o n t h e s w it c h b o d y .
P u ll o u t t h e k n o b a s s e m b ly .
L e n s s c re w s (8 6 ).
3 . T rim p a n e l s c r e w s ( 1 2 1 ).
B a tte r y g ro u n d c a b le to th e b a tte ry .
4 . T rim p a n e l (1 2 0 ).
5 . B e z e l (1 3 2 ).
LICENSE LAMP REPLACEMENTRV MODELS
6 . L ig h t s w itc h h a r n e s s ( 1 3 0 ) .
7. L ig h t s w itc h (1 3 3 ).

1. B a tte r y g r o u n d c a b le fr o m th e b a tte r y .
2.
H o u s in g r e ta in in g s c r e w s (9 2 ) o r b o lts (9 7 ).
+ 4*
1 . L ig h t s w itc h (1 3 3 ) .
2.
3. L en s.
4.

L ig h t s w itc h h a r n e s s (1 3 0 ).
3. B e z e l (1 3 2 ).
B u lb .
4 . T rim p a n e l (1 2 0 ).
5 . T rim p a n e l s c r e w s (1 2 1 ).
1 . B u lb .
6 . K n o b a s s e m b ly (1 3 1 ).
2. Lens.
3 . H o u s in g r e ta in in g s c r e w s ( 9 2 ) o r b o lts (9 7 ).
7. B a tte r y g r o u n d c a b le to th e b a tte r y .
4 . B a tte r y g r o u n d c a b le fr o m
th e b a tte ry .
REAR LAMP BULB REPLACEMENTG VAN

G-Van
1. B a tte r y g r o u n d c a b le fr o m
2.
B a tte r y g r o u n d c a b le fr o m th e b a tte ry .
L e n s h o u s in g r e ta in in g s c r e w s (1 0 1 ).
L a m p h o u s in g (1 0 0 ).
B u lb s o c k e t ( 5 2 a n d 5 3 ) b y s q u e e z in g t h e r e te n t io n
lo c k a n d r o ta tin g t h e s o c k e t c o u n te r c lo c k w is e .
B u lb fr o m
4-
th e b u lb s o c k e t (5 2 a n d 5 3 ).
P re s s th e
s w itc h .
knob
a s s e m b ly
P u ll o u t t h e k n o b a s s e m b ly .
r e ta in in g
p in
o n th e
lig h t
s w itc h
3 . T r im p la t e r e t a in in g s c r e w s ( 1 4 2 ) .
4 . T r im p la t e ( 1 4 0 ) .
5. B e z e l (1 4 3 ).
Install or Connect
6 . L ig h t s w itc h ( 1 4 4 ) .
7. L ig h t s w itc h h a r n e s s ( 1 4 5 )
B u lb in to t h e b u lb s o c k e t.
B u lb s o c k e t ( 5 2 a n d 5 3 ) in to th e h o u s in g .
Install or Connect
L a m p h o u s in g (1 0 0 ).
L e n s h o u s in g r e ta in in g s c r e w s (1 0 1 ).
B a tte r y g ro u n d c a b le to th e b a tte ry .
1 . L ig h t s w itc h
(1 4 4 ).
h a rn e s s
(1 4 5 )
fro m
th e
2 . L ig h t s w itc h (1 4 4 ).
REAR MARKER LAMP BULB

REPLACEMENTG VAN
|<-+| Remove or Disconnect (Figure
th e b a tte ry .
K n o b a s s e m b ly (1 4 1 ).
3.
2 3 )
B e z e l (1 4 3 ).
4 . T rim
p la te (1 4 0 ).
5 . T r im
p la te r e ta in in g s c r e w s (1 4 2 ).
6 . K n o b a s s e m b ly (1 4 1 ) in to t h e s w itc h (1 4 4 ).
2.
7. B a tte r y g r o u n d c a b le to th e b a tte r y .
H o u s in g r e ta in in g s c r e w s (1 1 3 ).
90.
C o n n e c to r
91.
R ear L am p
92.
S c re w
H a rn e s s
93.
L a m p A s s e m b ly
94.
T o o th e d W a s h e r
95.
B o lt
96.
N u t
F -0 0 8 7 5
Figure 21RV Model License Lamp
BARK UP SWITCH REPLACEMENT
Manual Trnsmission
|++| Remove or Disconnect (Figure 28)

1. B a tte ry g ro u n d c a b le fr o m
2.
th e b a tte ry .
B a c k u p s w itc h h a r n e s s (1 6 4 ).
1 . B a tte r y g ro u n d c a b le fr o m t h e b a tte r y .
2 . S w itc h a s s e m b ly h a r n e s s .
3 . S w itc h a s s e m b ly .
P l a c e g e a r s e l e c t o r in n e u t r a l .
3 . B a c k u p s w itc h (1 6 3 ).
4 . S e a l (1 6 2 ).

1. S e a l (1 6 2 ).
2.
B a c k u p s w itc h (1 6 3 ).
3.
B a c k u p s w itc h h a r n e s s (1 6 4 ).
4 . B a tte r y g ro u n d c a b le to th e b a tte ry .
S q u e e z e th e s w itc h ta n g s (1 5 1 ) to g e th e r .
L ift o u t t h e s w it c h a s s e m b l y ( 1 5 2 ) .
++ Install or Connect
1. S w itc h a s s e m b ly .
P l a c e g e a r s e l e c t o r in n e u t r a l .
A l i g n t h e a c t u a t o r ( 1 5 7 ) w i t h t h e c u t o u t ( 1 5 9 ) in
t h e s te e r in g c o lu m n ja c k e t (1 5 8 ).
In s e r t th e ta n g s (1 5 1 ) in to th e r e c ta n g u la r h o le s
(1 5 0 ).
P u s h d o w n o n th e s w itc h a s s e m b ly (1 5 2 ).
Adjust
tP
S w itc h b y m o v in g t h e g e a r s e le c to r to p a r k .
T h e a c t u a t o r w ill r a c h e t , p r o v id in g p r o p e r
s w itc h a d ju s tm e n t.
2. S w it c h a s s e m b l y h a r n e s s .
Figure 23Van Rear Marker Lamp
Figure 24RV Model Instrument Panel Trim Plate
131.
L ig h t S w it c h
132.
B ezel
133.
K n o b A s s e m b ly
Figure 25RV Model Light Switch
B -0 6 9 1 0
Figure 27Van Light Switch
150.
R e c ta n g u la r H o le
151.
Tang
152.
S w itc h
153.
B a c k U p S w itc h
T e r m in a l
154.
B a c k U p S w itc h
T e r m in a l
155.
P a rk , N e u tr a l S w itc h T e r m in a l
A s s e m b ly (A u to T r a n s .)
156.
P a rk , N e u tr a l S w itc h
157.
A c tu a to r
158.
S te e r in g
159.
C u to u t
160.
S h ift T u b e
C o lu m n
T e r m in a l
Jack et
161.
M a n u a l T r a n s m is s io n
162.
S eal
163.
S w itc h
164.
H a rn e s s
F -0 0 8 8 1
Figure 28Van Backup Lamp Switch
FUSESCIRCUIT BREAKERS SPECIFICATIONS

T h e w ir in g
c o m b in a tio n
lin k s in t h e w
e le c tr ic a lly c
c irc u its a r e p r o te c te d fr o m s h o r t c irc u its b y a

o f fu s e s , c ir c u it b r e a k e r s , a n d fu s ib le t h e r m a l
ir in g its e lf. T h is g r e a t ly r e d u c e s t h e h a z a r d o f
a u s e d f ir e s in t h e v e h ic le s .
T h e h e a d la m p c irc u its a r e p r o te c te d b y a c ir c u it b r e a k e r
in t h e lig h t s w i t c h . A n e l e c t r ic a l o v e r l o a d o n t h e b r e a k e r
w ill c a u s e t h e l a m p s t o g o o n a n d o f f , o r in s o m e c a s e s t o
r e m a in o ff.
In a d d i t i o n t o a f u s e , t h e w i n d s h i e l d w i p e r m o t o r is a l s o
p r o t e c t e d b y a c i r c u i t b r e a k e r . If t h e m o t o r o v e r h e a t s , d u e
to o v e r lo a d in g c a u s e d b y h e a v y s n o w , e t c ., t h e w ip e r s w ill
r e m a in s t o p p e d u n til t h e m o to r c o o ls .
F u s e s lo c a t e d in t h e J u n c t io n
o n th e d r iv e r s s id e a r e :
B lo c k b e n e a t h th e d a s h
RV TRUCK
H e a te r , F r o n t A /C , G e n e r a t o r W a r n in g
L a m p ..................................................................................................... 2 0 A m p
Id le S to p S o le n o id , A u x . B a tte r y , R a d io ,
T im e D e la y R e la y , E m is s io n C o n tr o l
S o le n o id , T r a n s m is s io n D o w n s h ift
( M 4 0 ) ..................................................................................................... 1 5 A m p
C ig a r e t t e L ig h t e r , C lo c k , D o m e L a m p ,
C a r g o L a m p ...................................................................................... 2 0 A m p
F u e l G a g e , B ra k e W a r n in g L a m p ,
T e m p e r a t u r e W a r n in g L a m p , O il
P r e s s u r e W a r n i n g L a m p .......................................................... 4 A m p
C o u rte s y L a m p , R o o f M a rk e r L a m p ,
L ic e n s e P la te L a m p , P a r k in g L a m p ,
S i d e M a r k e r L a m p , T a il L a m p ,
C l e a r a n c e L a m p ......................................................................... 2 0 A m p
D ir e c tio n a l S ig n a l In d ic a t o r L a m p , S to p
L a m p , T r a f f i c H a z a r d ................................................................ 1 5 A m p
In s t r u m e n t C lu s t e r L a m p , H e a t e r D ia l
L a m p , R a d io D ia l L a m p , C r u is e C o n tr o l
L a m p , W i n d s h i e l d W i p e r S w i t c h L a m p ..................... 4 A m p

C i g a r e t t e L i g h t e r , D o m e L a m p , S p o t L a m p ................1 5 A m p
W i n d s h i e l d W i p e r / W a s h e r ....................................................... 2 5 A m p
C r u is e C o n tr o l, R e a r W in d o w A u x .,
F u e l T a n k , T a c h o m e te r, B a c k -u p L a m p ,
D ir e c tio n a l S ig n a l In d ic a to r L a m p ,
D ir e c tio n a l S ig n a l L a m p , H e a d la m p
B u z z e r ................................................................................................. 1 5 A m p
F u e l G a g e , B ra k e W a rn in g L a m p ,
T e m p e r a tu r e W a rn in g L a m p , G e n e r a to r
W a r n in g L a m p , O il P r e s s u r e W a r n in g L a m p . . . .3 A m p
S t o p L a m p , T r a f f i c H a z a r d ....................................................... 1 5 A m p
A u x ilia r y B a tte r y , B a c k in g L a m p ,
P TRUCK
H e a t e r * , A i r C o n d i t i o n i n g * ....................................................... 2 5 A m p
In s tr u m e n t C lu s te r L a m p , W in d s h ie ld
W i p e r S w i t c h L a m p ...................................................................... 3 A m p
D ir e c tio n a l S ig n a l In d ic a to r L a m p , S to p
L a m p , T r a f f i c H a z a r d ................................................................ 1 5 A m p
F u e l G a g e , B r a k e W a r n i n g L a m p ...........................................3 A m p
L ic e n s e P la te L a m p , P a r k in g L a m p ,
S i d e M a r k e r L a m p , T a il L a m p ,
C l e a r a n c e L a m p , I d e n t i f i c a t i o n L a m p ........................ 1 5 A m p
W i n d s h i e l d W a s h e r / W i p e r ....................................................... 2 5 A m p
C ig a r e tte L ig h t e r * , C lo c k * , C o u r t e s y * ,
D o m e L a m p * .................................................................................. 1 5 A m p
A u x ilia r y B a t t e r y * , B a c k -u p L a m p ,
R a d i o ..................................................................................................... 1 5 A m p
Id le S to p S o le n o id , C r u is e C o n t r o l* ,
D ir e c tio n a l S ig n a l L a m p , T im e D e la y
R e la y , E m is s io n C o n t r o l S o le n o id ,
T r a n s m i s s i o n D o w n s h i f t ( M 4 0 ) ....................................... 1 0 A m p
I n - l in e f u s e s a r e l o c a t e d in t h e a u x il i a r y h e a t e r c ir c u it s
(C -K -P m o d e ls ) a n d u n d e r h o o d la m p , fr o n t a n d r e a r A /C
c ir c u its (C -K m o d e ls ).
* W h e n in c o r p o r a t e d b y b o d y b u ild e r .
D o n o t u s e f u s e s o f h ig h e r a m p e r a g e
re c o m m e n d e d a b o v e .
T h e fo llo w in g w ir in g
h a rn e s s e s
a re
th a n
th o s e
p ro te c te d
by
f u s ib l e l i n k w h ic h is a s p e c i a l w i r e i n c o r p o r a t e d in t h e
c ir c u it h e a d la m p h i- b e a m in d ic a to r , h o r n , a ir c o n d it io n in g
h ig h b lo w e r , ig n it io n c ir c u it s ( R V - P m o d e ls ) s t a r t e r
s o le n o id (p u ll-in a n d h o ld ) c ir c u it ( R V m o d e ls ). S h o u ld a n
e le c t r ic a l o v e r lo a d o c c u r , th is w ir e
d a m a g e to th e m a jo r h a rn e s s .
w ill fa il a n d
p re v e n t
G TRUCK
H e a t e r , A / C ........................................................................................... 2 5 A m p
Id le S to p S o le n o id , C r u is e C o n tr o l,
D ir e c t io n a l S ig n a l L a m p , D ir e c tio n a l
S ig n a l In d ic a to r L a m p , T r a n s m is s io n
D o w n s h i f t ( M - 4 0 ) ......................................................................... 1 0 A m p
R a d i o D i a l L a m p , R a d i o ....................................................... 1 5 A m p
In s tr u m e n t C lu s t e r L a m p , H e a t e r D ia l
L a m p , T ra n s m is s io n C o n tr o l L a m p
w ith T ilt W h e e l, C r u is e C o n tr o l
L a m p , W /S W ip e r S w itc h L a m p ,
H e a d l a m p B u z z e r ..........................................................................3 A m p
L ic e n s e L a m p , P a r k in g L a m p , S id e
M a r k e r L a m p , T a i l L a m p ....................................................... 1 5 A m p
W i n d s h i e l d W i p e r .............................................................................2 5 A m p
A n in - l in e f u s e is l o c a t e d in t h e A m m e t e r a n d t h e
a u x ilia r y h e a t e r c irc u its .
D o n o t u s e fu s e s o f h ig h e r a m p e r a g e r a tin g t h a n t h o s e
re c o m m e n d e d a b o v e .
T h e f o llo w in g w ir in g h a r n e s s e s a r e p r o te c te d b y a
f u s ib l e l in k w h ic h is a s p e c i a l w i r e i n c o r p o r a t e d in t h e
c ir c u it, ig n itio n , h o r n a n d h e a d la m p h i- b e a m in d ic a to r
c ir c u it s , a ir c o n d it io n in g h ig h b lo w e r . S h o u ld a n e le c t r ic a l
o v e r lo a d o c c u r , t h is w ir e w ill f a il a n d p r e v e n t d a m a g e to
th e m a jo r h a r n e s s .
CIRCUIT BREAKERS
DEVICE OR
CIRCUIT
PROTECTED
MODELS
AMPS.
R V -P -G
15
R V
30
35
H e a d la m p a n d
p a r k in g la m p
c ir c u it
T a ilg a te w in d o w
m o to r
R e a r A /C
(C 6 9 o v e rh e a d )
LOCATION
L am p
s w itc h
D ash
(fo r w a r d s id e )
D ash
(fo r w a r d s id e )
LAMP SPECIFICATIONS
LAMP BULB DATA
RV-P TRUCK
Q U A N .T R A D E #
U S E D IN
LAMP BULB DATA

G TRUCK
POW ER
U S E D IN
Q U A N .T R A D E #
2
O il p r e s s u r e in d ic a to r la m p
161
1 C P
G e n e r a t o r in d ic a to r la m p
194
2 C P
I n s t r u m e n t c l u s t e r l a m p s 11
161
1 C P
3 C P
H e a d la m p b e a m
la m p
161
1 C P
168
3 C P
P a r k , d ir e c tio n a l s ig n a l
la m p s
1157
3 -3 2 C P
T a il, s t o p la m p s
1157
3 -3 2 C P
1157
3 -3 2 C P
L ic e n s e L a m p 4
67
4 C P
D ir e c tio n a l s ig n a l
(fr o n t p a r k la m p s )6
1157
3 -3 2 C P
1
1
1004
2 1 1 -2
15 C P
12 C P
O il P r e s s u r e in d ic a to r la m p 1
168
3 C P
G e n e r a t o r in d ic a to r la m p 1
168
3 C P
In s tr u m e n t c lu s te r la m p s 2
168
H e a d la m p b e a m
la m p
L a m p a s s e m b ly ta il &
s to p la m p
in d ic a to r
H ead Lam ps
6014
5 0 -6 0 W
T e m p e r a t u r e in d ic a to r la m p
168
3 C P
D ir e c t io n a l s ig n a l in d ic a to r
la m p
168
3 C P
C le a r a n c e a n d m a r k e r la m p s
3 C P
R o o f m a r k e r la m p s 5
168
194
B r a k e w a r n in g in d ic a to r la m p
168
T r a n s m is s io n c o n tr o l (a u to )
B a c k in g la m p (e x c .
m o to r h o m e )
1
2
1445
1156
2 1 1 -2
POW ER
D o m e la m p s
D om e Lam ps:
C ab
U tility & S u r b u r b a n
12 C P
in d ic a to r
L ic e n s e la m p
67
4 C P
H e a d l a m p s 12
6014
5 0 -6 0 W
T e m p e r a t u r e in d ic a to r la m p
194
2 C P
D ir e c tio n a l s ig n a l in d ic a to r
la m p
194
2 C P
M a r k e r la m p s
168
3 C P
B r a k e w a r n in g in d ic a to r la m p
194
2 C P
B a c k -u p la m p
1156
32 C P
R a d io d ia l la m p
1893
2 C P
3 C P
H e a t e r o r A /C Iliu m , la m p
194
2 C P
0 .7 C P
T r a n s m is s io n c o n tr o l w /tilt
w h e e l Iliu m , la m p
1445
0 .7 C P
2 C P
32 C P
W /S w ip e r s w itc h la m p
161
1 C P
T r a n s m is s io n c o n tr o l Iliu m , la m p
73
.3 C P
C h o k e h e a t e r in d ic a to r la m p
1893
2 C P
S e a t b e lt w a r n in g la m p
194
2 C P
B a c k in g la m p (m o to r h o m e )
1295
50 C P
H e a t e r o r A /C Iliu m , la m p
161
1 C P
C o r n e r m a r k e r la m p s
7
67
4 C P
In s tr u m e n t c lu s te r la m p s 9
194
2 C P
C a r g o la m p (R V c a b )
1142
21 C P
I n s t r u m e n t c l u s t e r l a m p s 10
168
3 C P
R a d io d ia l la m p A M
A M /F M
1
1
216
216
1 C P
1 C P
C o u r te s y la m p
1003
15 C P
W in d s h ie ld w ip e r s w itc h la m p
161
1 C P
(p la tfo r m )
C lo c k la m p
168
3 C P
R e a r id e n t ific a t io n 7 la m p
10
1895
2 C P
U n d e r h o o d la m p
93
15 C P
S e a t b e lt w a r n in g la m p
168
3 C P
C a r g o /d o m e la m p
2 1 1 -2
12 C P
F o u r w h e e l d r iv e in d ic a to r la m p
161
1 C P
C h o k e h e a t e r in d ic a to r la m p
168
3 C P
1O n R V i n s t r u m e n t c l u s t e r s o n l y .
23 l a m p s u s e d o n i n s t r u m e n t c l u s t e r o n P m o d e l s o r R V w / o
gages.
3D o u b l e f i l a m e n t s e a l e d b e a m 6 0 W h i g h b e a m , 5 0 W l o w
beam .
"2 la m p s u s e d w ith s te p b u m p e r a n d P m o d e ls .
54 r e q u i r e d o n P m o d e l s .
61 1 5 7 N A , 2 . 2 - 2 4 C P o n R V m o d e ls .
7W i d e s i d e P i c k u p .
8 P t r u c k o n ly .
9G m o d e l w /o g a g e s ; 1 l a m p w it h g a g e s .
10 G m o d e l w / o g a g e s ; 3 l a m p s w i t h g a g e s .
G m o d e l w ith g a g e s o n ly .
12D o u b l e f i l a m e n t s e a l e d b e a m 6 0 W h i g h b e a m , 5 0 W
beam .
lo w
8C-1
SECTION 8C
INSTRUMENT PANEL
CONTENTS
SUBJECT
PAGE
Description........................................................................................................................................................... 8C- 2
Speedometer....................................................................................................................................................8C- 2
Fuel Gage......................................................................................................................................................... 8C- 2
Oil Pressure G age............................................................................................................................................ 8C- 2
Temperature Gage............................................................................................................................................ 8C- 2
Ignition Switch..................................................................................................................................................8C- 2
Lamp Switch......................................................................................................................................................8C- 2
Diagnosis Of Speedometer System.....................................................................................................................8C- 3
Diagnosis Of The Fuel Gage................................................................................................................................ 8C- 4
Diagnosis Of The Oil Pressure Gage...................................................................................................................8C- 5
Diagnosis Of The Temperature G age.................................................................................................................8C- 6
On Vehicle Service.............................................................................................................................................. 8C- 7
Speedometer Replacement.............................................................................................................................. 8C- 7
Speedometer Cable Core Replacement........................................................................................................... 8C- 7
Fuel Gage Replacement.................................................................................................................................. 8C- 9
Fuel Sender Unit Replacement.........................................................................................................................8C-11
Temperature Gage Replacement.....................................................................................................................8C-11
Temperature Gage Sensor Replacement......................................................................................................... 8C-13
Oil Pressure Gage Replacement.......................................................................................................................8C-13
Oil Pressure Gage Sensor Replacement......................................................................................................... 8C-14
Voltmeter Replacement.................................................................................................................................... 8C-14
Instrument Cluster Replacement.....................................................................................................................8C-15
Laminated (Printed) Circuit Replacement....................................................................................................... 8C-16
Ignition Switch Replacement...........................................................................................................................8C-16
Lamp Switch Replacement...............................................................................................................................8C-16
Special Tools........................................................................................................................................................8C-16
X-8732, Sec. 8C, Service Manual
8C-2 INSTRUMENT PANEL
DESCRIPTION
SPEEDOMETER
T h e
on
th e
in s tr u m e n t
p an el
is
m e c h a n ic a l t y p e t h a t is d r iv e n b y a c a s e d c a b le w h ic h is
c o n n e c t e d to t h e t r a n s m is s io n . T h e s p e e d o m e t e r is
lo c a t e d in t h e c e n t e r o f t h e i n s t r u m e n t p a n e l . R e f e r to
fig u r e 1 fo r d ia g n o s is .
FUEL GAGE
T h e f u e l g a g e is a n e le c t r ic a l, c u r r e n t s e n s in g t y p e o f
in d ic a t o r . It h a s t w o c o ils in it. O n e c o il s e t s u p a c o n s t a n t
m a g n e t ic f ie ld . T h e o t h e r c o il h a s a v a r y in g m a g n e t ic f ie ld
w h ic h is v a r ie d b y t h e r e o s t a t a t t a c h e d to a f lo a t in t h e f u e l
t a n k . A m a g n e t , a t t a c h e d to a p o in t e r , is lo c a t e d b e t w e e n
t h e t w o c o ils . T h e m a g n e t w ill e s t a b l is h a p o s it io n w h ic h is
c o n t r o lle d b y t h e m a g n e t ic f ie ld s o f t h e t w o c o ils . R e f e r to
fig u r e 2 fo r d ia g n o s is .
OIL PRESSURE GAGE

T h e o il p r e s s
T h e g a g e is e l e
w h ic h c o n tr o ls
R e fe r to fig u re
u r e g a g e d is p la y s t h e e n g i n e o il p r e s s u r e .
c t r ic a l. T h e s e n d e r is a v a r ia b le r e s is t a n c e
th e c u r r e n t p a s s in g th ro u g h th e g a g e .
3 fo r d ia g n o s is .
ENGINE CONTROL
IGNITION SWITCH
O n t h e R V a n d G m o d e ls , t h e ig n it io n s w it c h is lo c a t e d
in t h e s t e e r i n g c o lu m n o n t h e r ig h t h a n d s i d e j u s t b e lo w
t h e s t e e r in g w h e e l. T h e e le c t r ic a l s w it c h in g p o r tio n o f t h e
a s s e m b ly is s e p a r a t e f r o m t h e k e y a n d lo c k c y lin d e r .
H o w e v e r , b o t h a r e s y n c h r o n iz e d a n d w o r k in c o n ju n c t io n
w ith e a c h o th e r th r o u g h t h e a c tio n o f t h e a c tu a to r ro d
a s s e m b ly .
F o r a c o m p le t e e x p la n a t io n o f t h e k e y a n d lo c k c y lin d e r ,
a n d th e a c tu a to r ro d a s s e m b ly , r e fe r to S T E E R IN G
C O L U M N , (S e c . 3 B 4 ).
T h e ig n it io n a n d s t a r t in g s w it c h is k e y o p e r a t e d t h r o u g h
t h e a c t u a t o r r o d a s s e m b ly to c lo s e t h e ig n itio n p r im a r y
c ir c u it a n d to e n e r g iz e t h e s ta r tin g m o to r s o le n o id fo r
c r a n k in g .
O n t h e P m o d e ls t h e ig n it io n s w it c h is lo c a t e d o n t h e
in s tr u m e n t p a n e l. T h e s w itc h c o n tr o ls t h e e n g in e
s ta r t fu n c tio n s , a n d th e a c c e s s o r ie s .
T h e c o n n e c t io n s to t h e ig n itio n s w itc h a r e s h o w
W ir in g D ia g r a m s B o o k le t. T h e c h a r ts in c lu d e d
d ia g r a m s s h o w h o w th e s w it c h e s a r e in te r n a lly c o
in e a c h s w it c h p o s it io n .
ru n a n d
n in t h e
o n th e
n n e c te d
LAMP SWITCH
TEMPERATURE GAGE
T h is g a g e d is p la y s t h e t e m p e r a t u r e o f t h e e n g in e
c o o l a n t . I t i s a n e l e c t r i c a l g a g e . T h e g a g e s s e n d e r i s a
v a r ia b le r e s is t a n c e t h a t c o n tr o ls t h e c u r r e n t p a s s in g
th r o u g h th e g a g e . R e f e r to fig u r e 4 fo r d ia g n o s is .
T h e la m p s w itc h c o n tr o ls th e h e a d la m p s , m a r k e r
la m p s , r u n n in g la m p s a n d p a r k in g la m p s . T h e s w itc h a ls o
c o n tr o ls th e d o m e la m p s a n d
in s t r u m e n t illu m in a tio n la m p s .
th e
lig h t
le v e l
o f th e
INSTRUMENT PANEL 8C-3
DIAGNOSISSPEEDOMETER SYSTEM
PROBLEM
POSSIBLE CAUSE
CORRECTION
Noisy
Kinked, pinched or
burned casings.
Replace both the cable and

casing. Recheck for noise.
Bent cable tips.
Replace both the cable and

casing. Recheck for noise.
Improper or insufficient
lubrication of cable.
Lubricate cable core with P/N

6478535 or equivalent. Pack
ferrule with grease.
Faulty driven gear or

rough drive gear.
Remove driven gear assembly

from transmission. Check for
free rotation of gear in sleeve.
Check for burrs, flash or
unusual worn spots. If gears
appear faulty, replace and
recheck for noise.
Whine
Oversize driven gear stem

in transmission binds with
adapter.
Replace driven gear and stem.
Buzzing sound with

manual transmission.
Shift linkage vibration.
Adjust transmission shift

linkage.
Tick or ringing sound

with jumpy pointer
between 0 and 30 MPH.
Faulty cable.
Replace cable.
Sticky speedometer
pointer.
Speedometer pointer is
bent and rubs.
Remove speedometer cluster

or lens and straighten pointer.
Recheck speedometer operation.
Incorrect
calibration.
Wrong transmission
adapter, drive gear or
sleeve.
Check speedometer gear

reference for correct
application and replace if
necessary.
Oversize or undersize
tires.
Check calibration using

correct tire size.
ii
Faulty speedometer head.
Remove speedometer for repair.
11
it
11
F -0 0 9 3 0
Figure 1Diagnosis of the Speedometer
DIAGNOSIS OF THE FUEL GAGE
DISCONNECT FUEL GAGE

SENDER WIRE IN REAR
COMPARTMENT J-24538-A TESTER TO
SENDER WIRE & TO GROUND
TURN
IGNITION
ON
GO TO STEP 2
GAGE RESPONDS TO TESTER ACCURATELY
GO TO STEP 3
GAGE RESPONDS BUT NOT ACCURATELY
GO TO STEP 6
GAGE DOES NOT RESPOND
GO TO STEP 4
REPLACE SENDER
CHECK REAR COMPARTMENT

CONNECTOR & WIRES
TO SENDER
OK
REPAIR WIRE OR CONNECTOR
DISCONNECT FRONT BODY

CONNECTOR. CONNECT
J-24538-A TESTER TO LEAD THAT
GOES TO THE GAGE.
REMOVE
GAGE
CHECK FOR BAD

CONNECTIONS AT GAGE
TERMINALS OR INST
CLUSTER CONNECTOR
GAGE READS BETWEEN

1/4 & 1/2 WITH 90 OHMS
FROM J-24538-A
GAGE RESPONDS
TO TESTER ACCURATELY
CHECK WIRING BETWEEN REAR

COMPARTMENTS FRONT BODY
CONNECTOR
GAGE DOES
NOT RESPOND
GOOD
CONNECTIONS
BAD
CONNECTIONS
GO TO STEP 5
REPLACE GAGE
REPAIR
CONNECTIONS &
REINSTALL GAGE
NUTS LOOSE
REMOVE GAGE
AND CHECK FOR
LOOSE NUTS AT
GAGE TERMINALS
TIGHTEN NUTS
&
REINSTALL GAGE
NUTS TIGHT
GAGE IS INACCURATE
IN OTHER WAYS
REPLACE GAGE
F-00885
Figure 2Diagnosis of the Fuel Gage
Figure 3Diagnosis of the Oil Pressure Gage
DIAGNOSIS OF THE TEMPERATURE GAGE

DISCONNECT TEMP GAGE
SENDER WIRE
TURN
IGNITION
ON
GO TO STEP 2
CONNECT J-24538-A TESTER TO

SENDER WIRE & TO GROUND
GAGE RESPONDS TO TESTER ACCURATELY
REPLACE SENDER
GAGE DOES NOT RESPOND OR IS INACCURATE
GO TO STEP 3
GAGE INDICATES WELL BEYOND "H O T END OF SCALE
GO TO STEP 5
DISCONNECT TEMP. GAGE

LEAD AT ENGINE HARNESS
CONNECTOR. CONNECT J-24538-A
TESTER TO LEAD THAT
GOES TO THE GAGE
REMOVE
GAGE
REMOVE
GAGE
GAGE RESPONDS
TO TESTER ACCURATELY
GAGE DOES
NOT RESPOND
GOOD
CONNECTIONS
CHECK FOR BAD

CONNECTIONS AT GAGE
TERMINALS OR INST.
CLUSTER CONNECTOR
OR LOOSE NUTS AT
GAGE TERMINALS
BAD
CONNECTIONS
CHECK FOR LOOSE

NUTS AT GAGE
TERMINALS OR
LACK OF GROUND
CONNECTION TO GAGE
GOOD
CONNECTIONS
BAD
CONNECTIONS
CHECK WIRING
BETWEEN SENDER
CONNECTOR &
ENGINE HARNESS
CONNECTOR
GO TO STEP 4
REPLACE GAGE
REPAIR
CONNECTIONS &
REINSTALL GAGE
REPLACE GAGE
REPAIR
CONNECTIONS &
REINSTALL GAGE
F-00937
Figure 4Diagnosis of the Temperature Gage
ON VEHICLE SERVICE
SPEEDOMETER REPLACEMENT
El
i l Install or Connect
1. S p e e d o m e te r (8 0 ).
S e r v ic in g o f th e s p e e d o m e t e r a s s e m b ly s h o u ld o n ly b e
p e r f o r m e d b y t r a in e d t e c h n ic ia n s h a v in g t h e p r o p e r te s t
e q u ip m e n t.
W h e n r e p la c in g a s p e e d o m e te r o r o d o m e te r a s s e m b ly ,
t h e la w r e q u ir e s t h e o d o m e t e r r e a d in g o f t h e r e p la c e m e n t
u n it to b e s e t to r e g is te r th e s a m e m ile a g e a s th e p r io r
o d o m e t e r . If t h e s a m e m i le a g e c a n n o t b e s e t , t h e la w
r e q u ir e s th e r e p la c e m e n t o d o m e t e r b e s e t to z e r o a n d a
l a b e l b e i n s t a l l e d o n t h e d r i v e r s d o o r f r a m e t o s h o w t h e
p r e v io u s o d o m e te r r e a d in g a n d th e d a te o f r e p la c e m e n t.
2 . S p e e d o m e te r c a b le a s s e m b ly .
3 . T w o h e x h e a d s c r e w s a n d r u b b e r g r o m m e ts t h a t h o ld
th e s p e e d o m e te r a s s e m b ly to th e c lu s te r c o v e r.
4 . S p e e d o m e t e r d ia l r e ta in in g s c r e w s .
5 . In s tr u m e n t c lu s te r . R e fe r to
R e p l a c e m e n t in t h is s e c t io n .
In s tr u m e n t
C lu s te r
P MODELS
RV MODELS
1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry .

2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS
E L E C T R IC A L (S E C . 8 B ).
In s tr u m e n t
C lu s te r
3 . L a m p s o c k e t a s s e m b lie s .
4 . L a m in a t e d c ir c u it r e ta in in g n u ts .
5 . L a m in a te d c ir c u it.
3 . R a d io c o n tro l k n o b s .
6 . C lu s t e r c a s e r e ta in in g s c r e w s .
4 . C lo c k a d ju s te r s te m .
7. C lu s te r c a s e fr o m th e b e z e l.
5 . In s tr u m e n t c lu s te r b e z e l (4 3 ).
8 . S p e e d o m e t e r r e t a in in g b o lts .
6 . S t e e r in g c o lu m n c o v e r.
9 . S p e e d o m e te r fro m th e c lu s te r c a s e .
7. In s tr u m e n t c lu s te r le n s (4 2 ).
Install or Connect
8 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ) .
9 . R e ta in e r (4 4 ).
1. S p e e d o m e te r to th e c lu s te r c a s e .
1 0 . S p e e d o m e t e r c a b le .
2 . S p e e d o m e t e r r e ta in in g b o lts .
D e p r e s s s p r in g c lip ( 3 0 ).
R e m o v e c a b le a n d c a s e fr o m
th e s p e e d o m e te r
(3 6 ).
3.
C lu s te r c a s e to th e b e z e l.
5 . L a m in a te d c ir c u it.
7. L a m p s o c k e t a s s e m b lie s .
1. S p e e d o m e te r (3 6 ).
2 . S p e e d o m e te r c a b le a s s e m b ly .
P u s h t h e c a b le a s s e m b ly in to t h e s p e e d o m e t e r
h e a d , r o ta tin g t h e c a b le a s s e m b ly , u n til th e
s p r in g c lip e n g a g e s .
In s tr u m e n t
C lu s te r
9 . B a tte ry g ro u n d c a b le fro m th e b a tte ry .
SPEEDOMETER CABLE CORE

REPLACEMENT
3 . R e ta in e r (4 4 ).
4 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ).
5 . In s tr u m e n t c lu s te r le n s (4 2 ).
ALL VEHICLES
7. In s tr u m e n t c lu s te r b e z e l (4 3 ).
|++| Remove or Disconnect (Figures 5, 8 9, and

10)
1 0 . H e a d la m p s w itc h k n o b a s s e m b ly .
1. B a tte ry g r o u n d c a b le fr o m th e b a tte ry .
1 1. B a tte r y g r o u n d c a b le to th e b a tte r y .
2 . S p e e d o m e te r c a b le a s s e m b ly fr o m th e s p e e d o m e te r.
G MODELS
3.
C o m p r e s s t h e s p r in g c lip
P u ll t h e c a b le a s s e m b ly f r o m t h e s p e e d o m e t e r .
C a b le c o re .
2 . In s t r u m e n t c lu s te r. R e f e r to
In s tr u m e n t
C lu s te r
3 . S p e e d o m e t e r d ia l r e t a in in g s c r e w s .
4 . T w o h e x h e a d s c r e w s a n d r u b b e r g r o m m e t s s e c u r in g
th e s p e e d o m e te r a s s e m b ly to th e c lu s te r c o v e r.
5 . S p e e d o m e te r c a b le a s s e m b ly fr o m th e s p e e d o m e te r.
6 . S p e e d o m e te r (8 0 ).
+ -
(30).
P u ll t h e c o r e o u t o f t h e s p e e d o m e t e r e n d o f t h e
c a s in g . If t h e c a b le c o r e is b r o k e n , r e m o v e t h e
lo w e r p ie c e o f t h e c o r e fr o m t h e tr a n s m is s io n
e n d o f th e c a s in g .

L u b r i c a n t in t h e c a s i n g a n d o n t h e c o r e .
C o r e in to th e s p e e d o m e te r e n d o f th e c a s in g . T u rn th e
c o r e t o e n g a g e t h e d r i v e g e a r in t h e t r a n s m is s io n .
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
S peedom eter Cable Spring Clip

Lamp B ulb Socket
Lam inated C ircu it
C luster Case
In d ica to r Lamp F ilte r (Turn Signal)
Fuel Gage
S peedom eter
Tem perature Gage
Brake W arning Lamp F ilter
A m m eter
Oil Pressure Gage
Transm ission S h ift In dica to r
In strum en t C lu ster Lens
Instru m en t C luster Bezel
R etainer
F -0 0 9 4 5
Figure 5RV Model Instrument Panel
^ "-< ^ --6 0
32.
33.
50.
51.
52.
53.
54.
55.
56.

C luster Case
Fuel Gage C lip
Lamp Socket Hole
Speedom eter Hole
High Beam In d ica to r Lamp
O il Pressure In d ic a to r Lamp
Engine Temperature W arning Lamp
Brake W arning Lamp
57.
58.
59.
60.
61.
62.
63.
64.
Charging System Lamp

Instrum ent C lu ste r C onnecto r
A m m eter C lip
Brake W arning Lam p/C lock
Temperature Gage C lip
Fuel Gage C lip
Turn Signal In d ica to r Lamp
Brake W arning Lamp
F -0 0 9 5 3
Figure 6RV Model Laminated C ircuit

3 . S p e e d o m e t e r c a b le a s s e m b ly in to t h e
h e a d u n til t h e s p r in g c lip ( 3 0 ) e n g a g e s .
4 . B a tte r y g r o u n d c a b le to t h e b a tte r y .

1. F u e l g a g e (3 5 ).
2 . F u e l g a g e a tta c h in g s c re w s .
3 . C a s e fro n t c o v e r (4 4 ).
FUEL GAGE REPLACEMENT
4 . T r a n s m is s io n s h ift in d ic a to r (4 1 ).
6 . S te e r in g c o lu m n c o v e r.
1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS
1 1. B a tte r y g r o u n d c a b le to th e b a tte r y .
9 . C a s e fro n t c o v e r (4 4 ).
G MODELS
1. B a tte r y g r o u n d c a b le fr o m th e b a tte ry .
1 0 . F u e l g a g e a tta c h in g s c re w s .
2 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to
C lu s t e r R e p l a c e m e n t in t h is s e c t io n .
11. F u e l g a g e (3 5 ).
3. L e n s (8 3 ).
In s tr u m e n t
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
B olt (#8-32 x 7/ie")

S peedom eter M ounting B ushing
Nut
Flat W asher
Screw (#8-18 x 7/ie")
Engine C oolant Temperature Gage
V oltm eter
Screw (#8-16 x 7/ie")
R etainer
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
Speedom eter
Gage Mask
Lens Retainer
Lens
Bezel
Fuel Gage
Lamp
Engine Oil Pressure Gage
Instrum ent C luster W ith Gages
Instrum ent C luster W ith o u t Gages
F -0 0 9 6 0
Figure 7Van Instrum ent Panel
P MODELS
4 . L e n s r e ta in e r (8 2 ).
6 . L a m in a te d c ir c u it (7 4 ) fr o m t h e r e ta in e r (7 9 ).
B a tte r y g r o u n d c a b le fr o m th e b a tte r y .
In s tr u m e n t
7. F u e l g a g e r e ta in in g n u ts (7 2 ).
c lu s te r.
R e fe r
to
R e p l a c e m e n t in t h is s e c t i o n .
8. F u e l g a g e .
L a m p s o c k e t a s s e m b lie s .
L a m in a te d c ir c u it r e ta in in g n u ts .
L a m in a te d c irc u it.
C lu s t e r c a s e r e ta in in g s c r e w s .
1. F u e l g a g e to th e la m in a te d c ir c u it.
C lu s te r c a s e fr o m th e b e z e l.
2 . F u e l g a g e r e ta in in g n u ts (7 2 ).
3 . L a m in a te d c ir c u it (7 4 ) to th e r e ta in e r (7 9 ).
5 . L e n s r e ta in e r (8 2 ).
F u e l g a g e r e t a in in g b o lts .
F u e l g a g e fro m th e c lu s te r c a s e .
Install or Connect
1. F u e l g a g e to th e c lu s te r c a s e .
2 . F u e l g a g e r e t a in in g b o lts .
6. L e n s (8 3 ).
3 . C lu s te r c a s e to th e b e z e l.
7. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to
In s tru m e n t
5 . L a m in a te d c irc u it.
In s tr u m e n t
C lu s te r
2. Speedom eter Cable C o nnecto r

4. Transfer Case
F -0 0 8 8 3
Figure 9Speedom eter CableFour Wheel Drive

7. L a m p s o c k e t a s s e m b lie s .
8 . In s tr u m e n t c lu s te r . R e fe r to In s tr u m e n t
9 . B a tte ry g ro u n d c a b le fr o m th e b a tte ry .
C lu s te r
FUEL SENDER UNIT

REPLACEMENT
ALL MODELS
R e fe r to F U E L S Y S T E M S (S E C . 6 C ) o r th e F U E L A N D
E M IS S IO N S M a n u a l ( T B I v e h ic le s ) .
TEMPERATURE GAGE
REPLACEMENT
1. Speedom eter
2. Speedom eter Cable C onnecto r
3. Seal
RV MODELS
F -0 0 8 8 2

Figure 8Speedometer CableTwo Wheel Drive
2. Speedom eter Cable C onnecto r

4. Transfer Case
5.
6.
7.
8.
9.
10.
11.
12.
Sleeve
Gear
Transm ission
Retainer
Seal
Retainer
Sleeve A ssem b ly
Bolt
13.
14.
15.
16.
17.
18.
19.
20.
A dapter A sse m b ly P osition for All Transm issions Except SM465

A dapter A sse m b ly P osition For SM465 Transm ission
O utput Key
A dapter A sse m b ly Right A ngle
A dapter A ssem bly
In-Line A dapter A ssem bly (W ith SM465 Transm ission)
Parallel A dapter A ssem bly (Except SM465 Transm ission)
In-Line A dapter
F 00884
Figure 10Speedometer Adapter Assemblies
4 . C lo c k a d ju s t e r s te m .
1.
2.
6 . S t e e r in g c o lu m n c o v e r .
3.
Install or Connect
4.
8 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ).
5.
9 . R e ta in e r (4 4 ).
6.
1 0 . T e m p e ra tu r e g a g e a tta c h in g s c re w s .
7.
11. T e m p e ra tu re g a g e (3 7 ).
8.
9.
Temperature gage to the cluster case.

Temperature gage retaining bolts.
Cluster case to the bezel.
Cluster case retaining screws.
Laminated circuit.
Laminated circuit retaining nuts.
Lamp socket assemblies.
Instrument cluster. Refer to Instrument Cluster
Replacement in this section.
1. T e m p e ra tu re g a g e (3 7 ).
2 . T e m p e ra tu r e g a g e a tta c h in g s c re w s .
TEMPERATURE GAGE SENSOR

REPLACEMENT
3 . R e ta in e r (4 4 ).
5 . In s tr u m e n t c lu s te r le n d s (4 2 ).
A L L MODELS
CAUTION: Do n o t rem ove cap w ith th e e n g in e

h o t. A llo w th e v e h ic le to c o o l o ff firs t.
1 1. B a tte r y g r o u n d c a b le to t h e b a tte r y .
1. R a d i a t o r c a p .
G MODELS
L o o s e n t h e c a p to t h e fir s t s to p . T h is w ill r e lie v e

t h e c o o lin g s y s te m p r e s s u r e .
In s tr u m e n t
T ig h t e n t h e c a p . T h is w ill m in im iz e t h e lo s s o f
c o o la n t w h e n r e p la c in g th e te m p e r a tu r e s e n d e r.
S e n s o r h a rn e s s c o n n e c to r.
S e n s o r.
3 . L e n s (8 3 ).
4 . L e n s r e ta in e r ( 8 2 ).
H a v e t h e n e w s e n d e r r e a d y to in s ta ll o r c lo s e th e
s e n d e r h o l e w it h a c o r k in o r d e r t o m i n i m i z e
c o o la n t lo s s .
Install or Connect
6 . L a m in a t e d c ir c u it (7 4 ) fr o m t h e r e t a in e r (7 9 ).
7 . T e m p e r a t u r e g a g e r e ta in in g n u ts (7 2 ).
S e n s o r.
8 . T e m p e ra tu re g a g e (7 6 ).
S e n s o r h a rn e s s c o n n e c to r.
C o o la n t to r e tu r n t h e c o o la n t le v e l to t h e p r o p e r le v e l.

1. T e m p e r a t u r e g a g e (7 6 ) to t h e la m in a t e d c ir c u it.
OIL PRESSURE GAGE

REPLACEMENT
2 . T e m p e r a t u r e g a g e r e ta in in g n u ts (7 2 ).
3 . L a m in a te d c irc u it (7 4 ) to th e r e ta in e r (7 9 ).
4 . L a m in a te d c ir c u it r e ta in in g n u ts .
5 . L e n s r e ta in e r (8 2 ).
RV MODELS
6. L e n s (8 3 ).
In s tr u m e n t

1. B a tte r y g r o u n d c a b le fr o m th e b a tte ry .
P MODELS
|++| Remove or Disconnect
1. B a tte ry g r o u n d c a b le fr o m th e b a tte ry .
2 . In s t r u m e n t c lu s te r . R e f e r to
In s tr u m e n t
C lu s te r
9 . R e ta in e r (4 4 ).
1 0 . O il p re s s u r e g a g e a tta c h in g s c re w s .
5 . L a m in a te d c irc u it.
11. O il p r e s s u r e g a g e (4 0 ).
r+ J Install or Connect
8 . T e m p e r a t u r e g a g e r e t a in in g b o lts .
1. O il p r e s s u r e g a g e (4 0 ).
9 . T e m p e r a tu r e g a g e fr o m th e c lu s te r c a s e .
2 . O il p r e s s u r e g a g e a tta c h in g s c r e w s .

OIL PRESSURE GAGE
SENSOR REPLACEMENT
3 . R e ta in e r .
ALL MODELS
+ + Remove or Disconnect
2 . W ir in g h a r n e s s c o n n e c to r fr o m th e s e n s o r.
1 1. B a tte r y g r o u n d c a b le to th e b a tte ry .
G MODELS
L - 6 e n g i n e s t h e s e n s o r is lo c a t e d in t h e b lo c k
a b o v e th e s ta rte r.
V - 6 a n d V - 8 e n g i n e s t h e s e n s o r is lo c a t e d a t
t h e le f t f r o n t s id e o f t h e d is tr ib u to r .
V -8 (4 5 4 ) e n g in e s

1 . B a tte ry g ro u n d c a b le fr o m th e b a tte ry .
t h e s e n s o r is lo c a t e d a t t h e
r e a r le ft s id e o f t h e b lo c k .
In s tr u m e n t
3 . L e n s (8 3 ).
D ie s e l e n g in e s
h o u s in g .
L e ft s id e , a b o v e th e fly w h e e l
3. S e n s o r.
4 . L e n s r e ta in e r (8 2 ).
6 . L a m in a te d c ir c u it (7 4 ) fr o m th e r e ta in e r (7 9 ).
U s e T o o l J -2 1 7 5 7 .
Install or Connect
7. O il p r e s s u r e g a g e r e ta in in g n u ts (7 2 ).
1. S e n s o r.
8 . O il p r e s s u r e g a g e (8 7 ).
U s e T o o l J -2 1 7 5 7 .
2 . W ir in g h a r n e s s c o n n e c to r to th e s e n d e r .
3 . B a tte r y g r o u n d c a b le to t h e b a tte r y .
1. F u e l g a g e (8 7 ) to th e la m in a te d c irc u it.
2 . F u e l g a g e r e ta in in g n u ts (7 2 ).
3 . L a m in a te d c ir c u it (7 4 ) to th e r e ta in e r (7 9 ).
VOLTMETER REPLACEMENT
5 . L e n s r e ta in e r (8 2 ).
RV MODELS
6 . L e n s (8 3 ).
In s tr u m e n t
+ -
1. B a tte r y g ro u n d c a b le fr o m th e b a tte r y .
8 . B a tte ry g ro u n d c a b le to th e b a tte ry .
P MODELS
B a tte ry g ro u n d c a b le fr o m th e b a tte ry .
In s tr u m e n t c lu s te r . R e fe r to
In s tr u m e n t
C lu s te r
L a m in a t e d c ir c u it r e ta in in g n u ts .
9 . R e ta in e r (4 4 ).
L a m in a te d c ir c u it.
1 0 . V o ltm e te r a tta c h in g s c r e w s .
C lu s te r c a s e fr o m th e b e z e l.
1 1 . V o ltm e te r .
O il p r e s s u r e g a g e r e t a in in g b o lts .
O il p r e s s u r e g a g e fr o m th e c lu s te r c a s e .
1 . V o ltm e te r .
Install or Connect
2 . V o ltm e te r a t ta c h in g s c r e w s .
O il p r e s s u r e g a g e to th e c lu s te r c a s e .
3 . R e ta in e r (4 4 ).
O il p r e s s u r e g a g e r e t a in in g b o lts .
4 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ).
L a m in a te d c ir c u it.
L a m in a te d c ir c u it r e ta in in g n u ts .
In s tr u m e n t
c lu s te r .
R e fe r
to
In s tr u m e n t
C lu s te r
1 0 . H e a d la m p s w itc h k n o b a s s e m b ly .
B a tte r y g ro u n d c a b le fr o m th e b a tte ry .
1 1. B a tte r y g ro u n d c a b le to th e b a tte r y .

G MODELS
In s tr u m e n t b e z e l (4 3 ).
S p e e d o m e te r d r iv e c a b le .
B a tte r y g ro u n d c a b le fr o m th e b a tte r y .
In s tr u m e n t c lu s te r a s s e m b ly . R e f e r to
In s tr u m e n t
L a m in a t e d c ir c u it (7 4 ) fr o m t h e r e t a in e r (7 9 ).
V o lt m e t e r r e ta in in g n u ts (7 2 ) .
V o ltm e te r .

1. C l u s t e r .
2. C lu s t e r h a r n e s s c o n n e c t o r .
3 . F o u r c lu s te r r e ta in in g s c r e w s .
4 . S p e e d o m e te r d r iv e c a b le .
5 . In s tr u m e n t b e z e l (4 3 ).
6. E i g h t i n s t r u m e n t b e z e l r e t a i n i n g s c r e w s .
7. S t e e r in g c o lu m n c o v e r .
8. F o u r s t e e r i n g c o l u m n c o v e r r e t a i n i n g s c r e w s .
1. V o ltm e te r to t h e la m in a t e d c ir c u it.
2 . V o lt m e t e r r e ta in in t n u ts (7 2 ) .
3 . L a m in a te d c irc u it (7 4 ) to th e r e ta in e r (7 9 ).
5 . L e n s r e ta in e r (8 2 ).
6 . L e n s (8 3 ).
7. In s tr u m e n t c lu s te r a s s e m b ly . R e f e r to
H e a d la m p s w itc h k n o b a s s e m b ly .
11. B a t t e r y g r o u n d c a b l e t o t h e b a t t e r y .
10.
In s tr u m e n t
G MODELS
8 . B a tte ry g ro u n d c a b le to th e b a tte ry .
P MODELS
In s tr u m e n t
5 . L a m in a t e d c irc u it.
P u ll t h e to p o f t h e c lu s t e r a w a y
in s tr u m e n t p a n e l.
L ift o u t t h e b o t t o m o f t h e c lu s te r .
In s tr u m e n t c lu s te r h a r n e s s c o n n n e c to r.
8 . V o lt m e t e r r e ta in in g b o lts .
9 . V o ltm e te r fr o m t h e c lu s te r c a s e .
Install or Connect
V o ltm e te r to t h e c lu s t e r c a s e .
V o lt m e t e r r e ta in in g b o lts .
L a m in a t e d c ir c u it.
In s t r u m e n t c lu s te r . R e f e r to In s t r u m e n t
9 . B a tte r y g r o u n d c a b le fr o m th e b a tte r y .
INSTRUMENT CLUSTER
REPLACEMENT
B a tte ry g r o u n d c a b le fr o m th e b a tte ry .
P u ll o u t t h e d r iv e c a b le .
C lo c k s e t s te m k n o b .
In s t r u m e n t c lu s te r b e z e l r e ta in in g s c r e w s .
T w o lo w e r c lu s t e r r e ta in in g s c r e w s .
C lu s te r .
C lu s te r
1.
2.
3.
4.
5.
6.
7.
8.

P r e s s in t h e t a n g o n t h e s p e e d o m e t e r h e a d .
2 . In s t r u m e n t c lu s te r . R e f e r to
- 4 -
C lu s te r
1.
2.
3.
4.
5.
6.
7.
8.
| + j Remove or Disconnect (Figure 5)

2 . H e a d la m p s w itc h k n o b a s s e m b ly .
4 . F o u r s te e r in g c o lu m n c o v e r r e ta in in g s c r e w s .
5 . S te e r in g c o lu m n c o v e r .
fro m

C lu s t e r h a r n e s s c o n n e c t o r in to t h e c lu s te r.
C lu s te r .
T w o lo w e r c lu s t e r r e ta in in g s c r e w s .
In s t r u m e n t c lu s te r b e z e l r e ta in in g s c r e w s .
C lo c k s e t s te m k n o b .
B a tte ry g ro u n d c a b le to th e b a tte ry .
P MODELS
B a tte ry g ro u n d c a b le fr o m th e b a tte ry .
RV MODELS
6 . E ig h t in s tr u m e n t b e z e l r e ta in in g s c e r w s .
c lip ( 3 0 ) a t t h e s p e e d o m e t e r
10
L e n s (8 3 ).
L e n s r e ta in e r (8 2 ).
P r e s s th e s p r in g
(3 6 ).
P u ll t h e c a b le fr o m t h e s p e e d o m e t e r h e a d .
9 . F o u r c lu s te r r e ta in in g s c r e w s .
. C lu s te r h a r n e s s c o n n e c to r.
1 1 . C lu s te r .
P r e s s in t h e t a n g o n t h e s p e e d o m e t e r h e a d .
P u ll o u t o f t h e d r iv e c a b le .
In s tr u m e n t c lu s te r h a rn e s s c o n n e c to r.
In s tr u m e n t c lu s te r b e z e l s c re w s .
In s tr u m e n t c lu s te r fr o m th e d a s h p a n e l.
Install or Connect
In s tr u m e n t c lu s te r to t h e d a s h p a n e l.
In s tr u m e n t c lu s te r b e z e l s c re w s .
In s tr u m e n t c lu s te r h a r n e s s c o n n e c to r.
th e

4 . S p e e d o m e t e r d r iv e c a b le .
5 . B a tte r y g r o u n d c a b le fr o m t h e b a tte r y .
1. L a m in a te d c ir c u it (5 1 ) to th e c lu s te r c a s e (3 3 ).
LAMINATED (PRINTED)
CIRCUIT REPLACEMENT
ALL MODELS
2 . L a m in a t e d c ir c u it r e ta in in g s c e r w s .
3 . G a n d P m o d e ls .
F u e l g a g e te r m in a l n u ts .
A m m e te r te r m in a l n u ts .
4 . In s tr u m e n t c lu s te r la m p b u lb a s s e m b lie s (5 7 ).
5 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to In s tr u m e n t
IGNITION SWITCH
REPLACEMENT
1. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to In s tr u m e n t
2 . In s tr u m e n t c lu s te r la m p b u lb a s s e m b lie s (5 7 ).
3 . L a m in a t e d c ir c u it r e ta in in g s c r e w s .
4 . G a n d P m o d e ls .
F u e l g a g e te r m in a l n u ts .
T e m p e r a tu r e g a g e te r m in a l n u ts .
A m m e te r te r m in a l n u ts .
5 . L a m in a te d c ir c u it fr o m th e c lu s te r c a s e (3 3 ).
R e fe r to S T E E R IN G
C O L U M N
(S E C . 3 B 4 ).
LAMP SWITCH REPLACEMENT

R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ).
SPECIAL TOOLS
[ill
III)
V#-------- f
J-21757-03
O il P r e s s u r e
S e n d in g
U n it S o c k e t
W re n c h
B -0 7 6 6 7
Figure 11Special Tool
9-1
SECTION 9
ACCESSORIES
CONTENTS
SUBJECT
PAGE
Cruise C o n tro l........................................................................................................................................................ 9- 1

Description..........................................................................................................................................................9- 1
Diagnosis................................................................................................................................................................9- 3
On-Vehicle S ervice................................................................................................................................................ 9- 6
Vacuum Release Valve Replacement................................................................................................................. 9- 6
Clutch Release Switch Replacement................................................................................................................. 9- 6
Cruise Control Modual Replacement................................................................................................................. 9- 8
Multi-Function Switch Replacement................................................................................................................... 9-10
Servo Replacement............................................................................................................................................ 9-11
Radio................................................................................................... ....................................................................9-16
Description..........................................................................................................................................................9-16
Diagnosis................................................................................................................................................................9-16
Accessory Noise................................. ................................................................................................................ 9-16
Chart 1 System Diagnosis and Analysis........................................................................................................... 9-17
Chart 2 Noisy Part 1 .......................................................................................................................................... 9-18
Chart 3 Noisy Part 2 .......................................................................................................................................... 9-19
Chart 4 ECM or Digital Dash N oise................................................................................................................... 9-20
Chart 5 Ignition Noise........................................................................................................................................ 9-21
Chart 6 Antenna Noise Part 1 .............................................................. ............................................................9-22
Chart 7 Antenna Noise Part 2 ...........................................................................................................................9-23
Chart 8 Weak...................................................................................................................................................... 9-24
Chart 9 Alternator W hine...................................................................................................................................9-25
Chart 10 Dead.................................................................................................................................................... 9-26
Chart 11 T ap e.................................................................................................................................................... 9-27
Diagnostic RF Sniffer...........................................................................................................................................9-30
Radio Receiver Replacement.................................................................................................................................9-30
RV Models............................................................................................................................................................9-30
G Van....................................................................................................................................................................9-30
Antenna Replacement.............................................................................................................................................9-32
RV Models............................................................................................................................................................9-32
G Van....................................................................................................................................................................9-32
Speaker Replacement............................................................................................................................................ 9-32
RV Models............................................................................................................................................................9-32
G Van....................................................................................................................................................................9-35
CRUISE CONTROL
DESCRIPTION
C r u is e
c o n tro l
is
sp eed
c o n tro l
s y s te m
w h ic h
m a in t a in s a d e s ir e d v e h ic le s p e e d u n d e r n o r m a l d r iv in g
c o n d itio n s . H o w e v e r, s t e e p g r a d e s u p o r d o w n m a y c a u s e
v a r ia t io n s in t h e s e l e c t e d s p e e d s . T h e e l e c t r o n ic c r u i s e
c o n tr o l s y s te m h a s th e c a p a b ility to c r u is e c o a s t, r e s u m e
s p e e d , a c c e le r a te , a n d t a p - u p a n d t a p -d o w n (fig u r e
1 )T h e m a in p a rts o f th e c r u is e c o n tr o l s y s te m a r e th e
m o d e c o n tr o l s w itc h e s , c o n tr o lle r (m o d u le ), s e r v o u n it,
s p e e d s e n s o r, v a c u u m s u p p ly , e le c tr ic a l a n d v a c u u m
2'
1. Set/Coast Switch
2.
O ff/O n /R e s u m e /A c c e l S w itc h
3.
D ir e c tio n a l S ig n a l L e v e r
r e le a s e s w itc h e s , a n d e le c tr ic a l h a r n e s s .
T h e c r u is e c o n tr o l s y s te m u s e s v a c u u m to o p e r a te a
th r o ttle s e r v o u n it. T h e s e r v o u n it m a in t a in s a d e s ir e d
F ig u r e 1 M u lti-F u n c tio n L e v e r
F -0 2 4 2 5
9-2 ACCESSORIES
F -0 2 4 2 6
Figure 2Controller Module

v e h i c l e s p e e d b y t r a p p i n g v a c u u m in t h e s e r v o u n it a t t h e
p r o p e r s e r v o p o s itio n . T h e c o n tr o lle r m o n ito r s v e h ic le
s p e e d a n d s e r v o p o s itio n a n d o p e r a te s th e v a c u u m a n d
v e n t v a l v e s in t h e s e r v o t o m a i n t a in d e s ir e d s p e e d . T h e
c o n t r o lle r c o n t a in s a lo w s p e e d lim it w h ic h w ill p r e v e n t
s y s te m e n g a g e m e n t b e lo w a m in im u m s p e e d , a b o u t 2 5
m p h . T h e o p e r a t i o n o f t h e c o n t r o ll e r is c o n t r o ll e d b y m o d e
c o n t r o l s w i t c h e s l o c a t e d in t h e e n d o f t h e d ir e c t i o n a l
s ig n a l le v e r . T o d is e n g a g e t h e s y s te m , tw o r e le a s e
s w itc h e s a r e p r o v id e d . A n e le c tr ic a l r e le a s e s w itc h
m o u n te d o n th e b r a k e p e d a l b r a c k e t (a n d c lu tc h p e d a l
b r a c k e t o n v e h ic le s e q u ip p e d w ith m a n u a l tr a n s m is s io n )
d is e n g a g e s th e s y s te m e le c tr ic a lly w h e n th e b r a k e p e d a l
( o r c lu t c h p e d a l) is d e p r e s s e d . A v a c u u m r e le a s e v a lv e ,
m o u n te d o n th e b ra k e p e d a l b ra c k e t, v e n ts th e tra p p e d
v a c u u m in t h e s e r v o t o a t m o s p h e r e w h e n t h e b r a k e p e d a l
is d e p r e s s e d , a l lo w i n g t h e s e r v o u n it to q u i c k l y r e t u r n t h e
t h r o ttle to id le p o s itio n .
T h e c o n tr o lle r in te r p r e ts t h e p o s itio n o f th e s e r v o ,
p o s itio n o f th e m o d e c o n tr o l s w itc h e s a n d th e o u tp u
t h e s p e e d s e n s o r . In r e s p o n s e to t h e s e in p u t s ,
c o n tr o lle r e le c tr ic a lly s ig n a ls t h e o p e n in g o r c lo s in g o f
v e n t a n d v a c u u m s o le n o id v a l v e s in t h e s e r v o ( f i g u r e
c o n t r o ll e r is u s u a l l y
m o u n te d
on
th e
p e d a l b r a c k e t. F o r m o u n tin g lo c a tio n ,
O n - V e h ic le S e r v ic e p o r tio n o f th is s e c tio n .
th e
t of
th e
th e
2 ).
a c c e le r a to r
re fe r
to
th e
SERVO UNIT (Figure 3)

T h e s e r v o c o n s is ts o f a v a c u u m o p e r a te d d ia p h r a g m , a
n o r m a lly o p e n s o le n o id v a lv e to v e n t th e d ia p h r a g m
c h a m b e r to a t m o s p h e r e , a n o r m a lly c lo s e d s o le n o id v a lv e
to c o n n e c t th e d ia p h g r a m c h a m b e r to th e v a c u u m s o u r c e ,
a n d a v a r ia b le in d u c ta n c e p o s itio n s e n s o r. T h e s e r v o
o p e r a t e s t h e t h r o t t le in r e s p o n s e t o s i g n a l s f r o m t h e
e le c t r o n ic c o n t r o lle r a s f o llo w s :
Steady Cruise State

B o th
(s y s te m
e n g a g e d an d
vacuum
a n d v e n t v a lv e s a r e
c lo s e d o r s e a le d .
o n th e d ia p h r a g m
o n th e v a c u u m
d ia p h g r a m c h a m b
T h e s e rv o h a s a c o n s ta n t v a c u u m
a n d p la c e s n o -flo w r e q u ir e m e n ts
s o u rc e . V a c u u m
is t r a p p e d in
e r.
o p e r a tin g )
51.
52.
53.
54.
55.
Servo
Valve (To Vacuum Supply)
Valve (To Vacuum Brake Release Valve)
Vacuum Solenoid and Valve
(N orm ally Closed)
T h ro ttle A ttachm ent
Variable Inductance P osition Sensor
Vent Solenoid and Valve
(N orm ally Opened)
Coil
Steel Core
F -0 2 4 2 7
Figure 3Servo Unit
ELECTRONIC CONTROLLER (MODULE)
T h e
35.
40.
41.
50.
ACCESSORIES 9-3
Vehicle Losing Speed
(d u e
to
s te e p
g ra d e s
or
c o n tro l
s w itc h e s )
T he
c o n tr o lle r
vacuum
s o le n o id to o p e n t h e v a c u u m
A n o p e n v a r i a b l e i n d u c t a n c e p o s i t i o n s e n s o r c o il in
th e s e rv o .
d r iv e r w is h e s to in c r e a s e s p e e d b y o p e r a tin g m o d e
th e
A lo s s o f e le c tr ic a l p o w e r to th e s y s te m .
v a lv e to th e
T h e ig n it io n is t u r n e d o ff.
e n e rg iz e s
v a c u u m s o u r c e . T h i s i n c r e a s e s t h e v a c u u m l e v e l in
th e s e r v o to in c r e a s e t h e th r o ttle o p e n in g . T h e v e n t
r e m a in s c lo s e d .
Vehicle Gaining Speed ( d u e t o s t e e p g r a d e s o r
d r iv e r w is h e s to d e c r e a s e s p e e d b y o p e r a tin g m
c o n tr o l s w itc h e s ) T h e c o n tr o lle r d e - e n e r g iz e s
v e n t s o le n o id to o p e n th e v e n t v a lv e to
a t m o s p h e r e w h ic h r e d u c e s v a c u u m in t h e s e r v o
a llo w s t h e th r o ttle r e tu r n s p r in g to d e c r e a s e
ode
th e
th e
and
th e
th r o ttle o p e n in g . T h e v a c u u m v a lv e r e m a in s c lo s e d .
W h e n t h e c r u is e s y s t e m is e n g a g e d a n d o p e r a t in g
(w ith o u t a n y in te r fe r e n c e fr o m th e d r iv e r v ia th e m o d e
c o n t r o l s w it c h e s ) , n o s p e e d c o r r e c t io n w ill b e m a d e u n til
t h e v e h i c l e e x c e e d s a p p r o x i m a t e l y AU m p h o f s e t
speed.
W h e n th e c o n tr o lle r s e n s e s a n o v e r o r u n d e r s p e e d
c o n d i t i o n it w ill p u l s e t h e o p e n i n g o f t h e v e n t o r v a c u u m
v a lv e . T h e a v e r a g e d u r a t io n o f o n e p u ls e w ill b e 1 0
m illis e c o n d s . T h e p u ls e w ill b e r e p e a t e d , a s r e q u ir e d ,
u n til t h e s p e e d c o r r e c tio n r e q u ir e d b r in g s t h e v e h ic le to
th e s e t s p e e d . F ro m a n y s e t s p e e d , u n d e r n o rm a l ro a d
lo a d c o n d i t io n s , t h e v a c u u m v a l v e w ill r e m a i n in a
c o m p le te ly o p e n p o s itio n w h e n v e h ic le s p e e d h a s
d r o p p e d 5 m p h b e lo w s e t s p e e d . L ik e w is e , w h e n v e h ic le
s p e e d h a s e x c e e d e d 3 m p h o v e r th e s e t s p e e d , s u c h a s
d o w n a s t e e p g r a d e , t h e v e n t w ill g o in t o c o n s t a n t o p e n
SPEED SENSORS
VSS Buffer Amplifier (Figure 4)
T h is is t h e d e v ic e t h a t w ill s u p p ly t h e v e h ic le s p e e d
in p u t to t h e c o n tr o lle r . T h e o p tic h e a d p o r tio n o f t h e
v e h i c l e s p e e d s e n s o r ( V S S ) is l o c a t e d in t h e s p e e d o m e t e r
f r a m e . A r e f le c t iv e b l a d e is a t t a c h e d t o t h e s p e e d o m e t e r
c a b le /h e a d a s s e m b ly . T h e r e f le c t iv e b la d e s p in s lik e a
p r o p e lle r , w it h its b la d e s p a s s in g t h r o u g h a lig h t b e a m
f r o m a L .E . D . in t h e o p t ic h e a d . A s e a c h b la d e e n t e r s t h e
L . E . D . l ig h t b e a m , l ig h t is r e f l e c t e d b a c k t o a p h o t o c e l l in
th e o p tic h e a d c a u s in g a lo w p o w e r s p e e d s ig n a l to b e
s e n t to a b u ffe r fo r a m p lific a tio n a n d s ig n a l c o n d itio n in g .
T h is a m p lif ie d s ig n a l is t h e n s e n t to t h e c o n t r o lle r .
VACUUM SUPPLY
T h e v a c u u m s u p p ly to o p e r a te th e c r u is e c o n tr o l s y s te m
is r o u t e d to t h e s e r v o . T h is c a n b e d o n e b y r o u t in g
m a n if o ld v a c u u m s tr a ig h t to t h e s e r v o o r fr o m m a n if o ld
th ro u g h a v a c u u m s to ra g e ta n k .
ELECTRICAL AND VACUUM

RELEASE SWITCHES
p o s itio n .
T h e s e r v o in c o r p o r a te s a s te e l c o r e w h ic h m o v e s w ith in
a c o il. Its r e s u lt in g v a r ia b le in d u c t a n c e p r o v id e s a
c o n t in u o u s ( v o lt a g e ) s e r v o p o s it io n s ig n a l to t h e c o n t r o lle r .
T h i s v o lt a g e s i g n a l is c o n s t a n t l y c o m p a r e d to t h e v e h ic le
s p e e d s i g n a l . T h i s c o m p a r i s o n d e t e r m i n e s if t h e p u l s e s
i s s u e d h a v e c o r r e c t e d t h e s p e e d e r r o r o r if a d d i t i o n a l
p u l s e s a r e r e q u ir e d . T h i s c o m p a r i s o n is a ls o u s e d to
l e n g t h e n t h e a v e r a g e p u l s e w h e n it is n o t e n o u g h t o
T h e s e s w itc h e s a r e u s e d to d is e n g a g e th e c r u is e
c o n tr o l s y s te m . A n e le c tr ic a l r e le a s e s w itc h m o u n te d o n
th e b r a k e p e d a l b r a c k e t (a n d c lu tc h p e d a l b r a c k e t o n
v e h ic le s e q u ip p e d w ith m a n u a l tr a n s m is s io n ) d is e n g a g e s
t h e s y s t e m e l e c t r i c a l l y w h e n t h e b r a k e ( o r c l u t c h ) p e d a l is
d e p r e s s e d . T h i s is d o n e b y in t e r r u p t in g t h e f lo w o f c u r r e n t
to t h e c o n tr o lle r . A v a c u u m r e le a s e v a lv e , m o u n t e d o n t h e
b r a k e p e d a l b r a c k e t v e n t s t h e t r a p p e d v a c u u m in t h e
s e r v o to a t m o s p h e r e w h e n t h e b r a k e p e d a l is d e p r e s s e d ,
a llo w in g t h e s e r v o u n it to m o r e q u ic k ly r e ta in t h e th r o ttle
to id le p o s it io n . T h is is d o n e b y r o u t in g a s e p a r a t e h o s e
d ir e c tly to t h e s e r v o fr o m t h e n o r m a lly c lo s e d v a c u u m
c o m p e n s a te fo r th e s p e e d e rro r, s u c h a s a s te e p g ra d e .
T h e s e r v o w ill g o in to a n o p e n v e n t - v a lv e p o s it io n u n d e r
t h e f o llo w in g c o n d itio n s :
W h e n t h e b r a k e ( o r c lu t c h ) p e d a l is d e p r e s s e d .
s w itc h . T h e s e tw o ty p e s o f
b e c o m b in e d w ith s to p
C o n v e r te r C lu tc h ) s w itc h
T ra n s m is s io n (S e c . 7 A ) O n -V
s w it c h e s w ill a
lig h t s w itc h ,
, e tc . R e fe r
e h ic le S e r v ic e
ls o s o m e tim e s
T C C (T o rq u e
to A u to m a tic
in t h is s e c t io n .
DIAGNOSIS OF CRUISE CONTROL SYSTEM

Inoperative System
(Electrical)
CORRECTION
POSSIBLE CAUSE
PROBLEM
1.
N o p o w e r to m o d u le t e r m in a ls G a n d
A (fig u re 5 ).
1.
C h e c k , r e p a ir , a d ju s t o r r e p la c e th e
fu s e , b r a k e a n d c lu tc h s w itc h e s , tu r n
s i g n a l l e v e r , w i r e s in t h e s t e e r i n g c o l
um n.
9-4 ACCESSORIES
DIAGNOSIS OF CRUISE CONTROL SYSTEM (CONT.)

PROBLEM
Inoperative System
(Electrical) (Cont.)
POSSIBLE CAUSE
2.
3.
4.
5.
6.
Inoperative System
(Mechanical)
n
o
o
n
a
g r o u n d c ir c u its to th e m o d u le ,
o r b u ffe r. M o d u le te r m in a l J , H a n d
te r m in a l C .
le a d s to o r a t th e s e r v o te r m in a ls
n d D (s e r v o p o s itio n s e n s o r ).
O p e n le a d s to
a n d E (v e n t
N o h ig h a n d
m o d u le s p e e d
o r a t s e rv o te rm
a n d v a c u u m c ir c
lo w v o lt a g e s ig n
s e n d e r te r m in a l
in a ls A
u its ).
a l a t th e
D .
7.
In c o r r e c t in p u t s ig n a ls to th e m o d u le ,
S e t/C o a s t o r R e s u m e /A c c e le r a te te r m i
n a ls (fig u r e 8 ).
P o o r c o n n e c tio n s a t th e m o d u le .
8.
C r u is e c o n tr o l m o d u le .
1.
N o vacuum
s e rv o .
2.
Vehicle Surges
(Electrical)
O p e
s e rv
s e rv
O pe
B
CORRECTION
at
th e
s m a ll
hose
to
th e
C o c k e d s e r v o p o s itio n ro d a n d s p r in g .
L e a k y s e r v o , b r o k e n f it tin g s , a n d /o r in o p
3.
4.
e r a tiv e v a lv e s .
D is c o n n e c t e d s e r v o lin k a g e .
M is a d ju s te d o r le a k y v a c u u m
v a lv e o r h o s e .
1.
2.
2.
3.
4.
C h e c k th e g r o u n d c ir c u its fo r lo o s e o r
b ro k e n c o n n e c tio n s . C le a n a n d r e p a ir
as needed.
R e p a ir th e le a d s o r r e p la c e th e s e rv o
(fig u r e s 6 a n d 7 ).
R e p a ir th e le a d s o r r e p la c e th e s e rv o .
5.
C h e c k , r e p a ir , r e p la c e : o p e n le a d s , b a d
p r i n t e d c i r c u i t fo il a t t h e c lu s t e r , b a d
b u f f e r a m p lifie r , t e r m in a l B o f s e r v o
to B o f b u ffe r, g ro u n d fo r b u ffe r, fo r
e ig n m a t e r i a l o r g r e a s e in s p e e d o m e t e r
head.
6 . C h e c k , r e p a ir , r e p la c e : o p e n le a d s ,
o p e n c o n n e c to r , b a d tu r n s ig n a l le v e r
a n d t e r m i n a l in t h e p r o p e r c a v it y .
7. C le a n , r e p a ir th e m o d u le c o n n e c to r a s
needed.
8 . R e p la c e th e m o d u le .
1.
C heck
2.
n e c te d v a c u u m h o s e s , in c o r r e c tly p o s i
tio n e d 3 -p o r t o r 2 -p o r t c h e c k v a lv e ,
r e s t r ic t e d e n g in e v a c u u m f ittin g .
R e p la c e th e s e rv o . R e p la c e th e s e rv o .
fo r
p lu g g e d ,
p in c h e d ,
d is c o n
3.
4.
R e c o n n e c t.
C h e c k f o r l e a k in v a c u u m r e le a s e h o s e
o r v a lv e o r m is a d ju s te d v a c u u m d u m p
s w itc h .
In te r m itte n t g r o u n d .
1.
I n t e r m i t t e n t o p e n in t h e v a c u u m , v e n t ,
S P S ( S e r v o P o s itio n S e n s o r ) le a d s o r
c o n n e c to r s o r te r m in a ls o r s e r v o .
S p ik e s o n t h e p o s itiv e b a t t e r y lin e (T r a n
s ie n t).
2.
C h e c k fo r p o o r g r o u n d in g to th e s e r v o
m o d u le , V S S ( V e h ic le S p e e d S e n s o r )
b u f f e r . If c h a s s i s g r o u n d is s u s p e c t , a t
ta c h a n e w g ro u n d s tra p b e tw e e n th e
c o w l a n d e n g in e b lo c k . R e t o r q u e a ll
g ro u n d c o n n e c tio n s .
D o a p h y s ic a l a n d a n e le c tr ic a l in s p e c
t io n a s s h o w n in t h e t e s t c h a r t s .
4.
T u rn s ig n a l, r a d io o r o th e r e le c tr ic a l d e
v ic e in te r fe r e n c e .
4.
5.
W r o n g m o d u le p a r t n u m b e r .
5.
n o d e f e c t is f o u n d , r e p l a c e t h e m o d u le .
R e p la c e th e m o d u le w ith a c o r r e c t p a r t
n u m b e r.
6.
C r o s s e d v a c u u m a n d v e n t e le c tr ic a l
le a d s b e tw e e n th e m o d u le a n d s e rv o .
6.
R e w ir e .
3.
r e le a s e
3.
C h e c k fo r a n y h o t w ir e s in te r m itte n tly
m a k in g c o n ta c t w ith c h a s s is g ro u n d .
R e p a ir a s r e q u ir e d .
R e p o s itio n e le c tr ic l le a d s a w a y fr o m
c r u is e o r V S S (V e h ic le S p e e d S e n s o r )
b u f f e r l e a d s . C h e c k f o r p o o r g r o u n d s . If
ACCESSORIES 9-5

Vehicle Surges
(Mechanical)
CORRECTION
POSSIBLE CAUSE
PROBLEM
1.
E x c e s s s l a c k in s e r v o l in k a g e .
1.
2.
3.
S e r v o v a lv e s tic k in g .
M is a d ju s te d o r le a k y
2.
3.
tio n .
R e p la c e th e s e rv o .
C h e c k f o r l e a k in v a c u u m r e l e a s e h o s e ,
o r v a lv e , o r m is a d ju s te d v a c u u m d u m p
4.
5.
D r y o r o v e r lu b e d s p e e d o c a b le .
S p e e d o m e te r p o in te r s h a k e :
D u e to m is r o u te d s p e e d o m e te r c a b le
a n d c a s in g a s s e m b ly .
T ra n s m is s io n s p e e d o m e te r d r iv e o r
4.
5.
v a lv e .
L u b r ic a t e to s p e c ific a tio n s .
R e r o u te o r r e p la c e th e c a b le
s e m b ly .
R e p la c e c o m p o n e n t.
6.
In s p e c t h o s e s a n d
q u ire d .
R e p a ir o r r e p la c e .
vacuum
r e le a s e
7.
d r iv e n g e a r.
R e s tr ic te d (k in k e d o r le a k in g ) v a c u u m
s u p p ly h o s e to a c c u m u la to r o r s e r v o .
B in d in g s e r v o lin k a g e d u e to in te r fe r
8.
e n c e , ru s t, e tc .
M is a d ju s te d o r
6.
le a k y
vacuum
7.
r e le a s e
8.
speedo
9.
9.
10.
11.
12.
G re a s e
or
fo r e ig n
m a te r ia l
in
head.
T o r q u e c o n v e r te r c lu tc h c u ttin g
o u t, o r t r a n s m is s io n s h iftin g .
A d ju s t to r e q u ir e m e n t s o u t lin e d in t h e
O n - V e h ic l e S e r v ic e p o r t io n in t h is s e c
C
h
d
C
r e p o s itio n
and
as
as
re
h e c k f o r l e a k in t h e v a c u u m r e l e a s e
o s e o r v a lv e , o r m is a d ju s te d v a c u u m
u m p s w itc h .
le a n o r r e p la c e .
and
10.
E n g i n e c u t s in a n d o u t d u e t o m i x t u r e
ig n itio n p r o b le m .
In c o r r e c tly p o s itio n e d 3 p o r t o r 2 p o rt
11.
(N o t a c r u is e p r o b le m .) C h e c k T V c a b le
a d ju s t m e n t o n th e tr a n s m is s io n . R e fe r
to s e c tio n 7 A .
R e p a ir a n d /o r a d ju s t a s r e q u ir e d .
12.
M a k e c o r r e c tio n .
in
c h e c k v a lv e .
Cruise Set Speed
No Resume Function
1.
E x c e s s s l a c k in s e r v o l in k a g e .
2.
In c o rr e c t m o d u le p a rt n u m b e r u s a g e .
1.
2.
3.
4.
No Tap Down
Function
1.
I n c o r r e c t o p e r a t o r t e c h n i q u e . ( I f R / A is
h e ld d o w n fo r m o r e t h a n 1 s e c o n d , t h e
s y s te m r e v e r ts to th e a c c e le r a to r m o d e .
T h e s p e e d a t t h e t i m e o f r e le a s e is t h e
n e w c r u is e s p e e d ).
O p e n c o n n e c tio n a t te r m in a l A o f th e
m o d u l e o r t h e t e r m in a l is in t h e w r o n g
c a v ity .
In te r m itte n t O n /O ff S w itc h .
In c o r r e c t o p e r a to r te c h n iq u e . (S e t/C o a s t
s w i t c h h e ld d o w n in e x c e s s o f .4 s e c o n d s
r e s e t s s p e e d w h e n t h e S e t / C o a s t is r e
le a s e d ).
1 . A d j u s t t o r e q u ir e m e n t s o u t l in e d in t h e
O n - V e h i c l e S e r v i c e p o r t io n in t h is s e c
tio n .
2 . In s ta ll a m o d u a l w ith th e c o r r e c t p a r t
n u m b e r.
3.
R e p la c e .
1.
A d v is e th e o p e ra to r.
2.
R e p a ir .
3.
4.
R e p la c e .
R e p la c e
1.
A d v is e o p e ra to r.
9-6 ACCESSORIES

P R O B L E M
U n w a n te d C r u is e o r
A c c e le ra tio n
P O S S IB L E C A U S E
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
C O R R E C T IO N
C r o s s e d v a c u u m a n d v e n t w ire s .
D e fe c tiv e o r in te r m itte n t tu rn s ig n a l
m o d e c o n tr o l s w itc h e s .
S t i c k i n g v a l v e s in t h e s e r v o .
B in d in g th r o ttle lin k a g e d u e to in te r fe r
e n c e , r u s t o r o th e r c o n ta m in a n ts .
G r e a s e in t h e s p e e d o m e t e r h e a d .
F lo o r m a t in te r fe r e n c e .
L o o s e r e t a in e r o n t h e b a il o f t h e s e r v o .
G r o u n d c ir c u it.
S p e e d s e n s o r b u ffe r.
In c o r r e c t m o d u le .
1.
2.
R e w ir e .
R e p la c e th e le v e r.
3.
4.
R e p la c e s e rv o .
C o r r e c t a s r e q u ir e d .
5.
6.
7.
8.
9.
10.
S
R
R
C
R
R
e r v ic e s p e e d o m e te r.
e p o s itio n a s r e q u ir e d .
e p la c e s e rv o .
le a n a n d r e p a ir a s r e q u ir e d .
e p la c e .
e p la c e .
Cruise Disengages
While Tapping Down
R e p la c e m o d u le .
Occasional Missed
Cruise Sets
R e p la c e m o d u le .
ON-VEHICLE SERVICE
VACUUM RELEASE VALVE
REPLACEMENT
CLUTCH RELEASE SWITCH

REPLACEMENT

In s tr u m e n t p a n e l h a r n e s s c o n n e c to r (8 ).
1. C o n n e c to r (9 8 ).
V acuum
2.
lin e s (1 0 ).
R e t a in e r (1 2 ). T u r n t h e r e t a in e r c o u n t e r c lo c k w is e to
u n s e a t it.
4. V acu u m
2 . V a c u u m r e l e a s e v a l v e ( 9 o r 1 1 ) u n t il it is s e a t e d o n
t h e r e t a in e r , w it h t h e b r a k e p e d a l in t h e d e p r e s s e d
p o s itio n .
3 . C lu tc h r e le a s e s w itc h (9 9 ).
N o te t h a t a u d ib le c lic k s c a n b e h e a r d a s th e
t h r e a d e d p o r t io n o f t h e v a lv e is p u s h e d t h r o u g h t h e

1 . R e t a in e r (1 0 2 ) . L in e u p t h e n o t c h e s o n
p e d a l b r a c k e t (1 0 1 ) to t h e r e ta in e r .
P u ll t h e b r a k e p e d a l f u lly r e a r w a r d a g a in s t t h e p e d a l
s to p , u n til t h e a u d ib le c lic k s o u n d s c a n n o lo n g e r
R e le a s e th e b r a k e p e d a l a n d r e p e a t s te p 2 to a s s u r e
th a t n o a u d ib le c lic k s o u n d s r e m a in .
3. V a c u u m
lin e s (1 0 ).
4. Instrument panel harness connector (8).
c lu tc h
N o te th a t a u d ib le c lic k s c a n b e h e a r d a s th e
t h r e a d e d p o r t io n o f t h e v a lv e is p u s h e d t h r o u g h t h e
r e ta in e r to w a r d th e b r a k e p e d a l.
P u ll t h e b r a k e p e d a l fu lly r e a r w a r d a g a in s t t h e p e d a l
s to p , u n til th e a u d ib le c lic k s o u n d s c a n n o lo n g e r
b e h e a rd .
R e le a s e th e b ra k e p e d a l a n d r e p e a t s te p 2 to a s s u r e
th a t n o a u d ib le c lic k s o u n d s r e m a in .
b e h e a rd .
th e
2 . C l u t c h r e l e a s e s w i t c h ( 9 9 ) u n t i l it is s e a t e d o n t h e
r e t a in e r , w it h t h e b r a k e p e d a l in t h e d e p r e s s e d
p o s itio n .
r e ta in e r to w a r d th e b r a k e p e d a l.
R e t a in e r (1 0 2 ). T u rn th e r e ta in e r c o u n te r c lo c k w is e to
u n s e a t it.
r e le a s e v a lv e .
1 . R e t a i n e r ( 1 2 ) . T u r n t h e r e t a i n e r c l o c k w i s e t o s e a t it.
3. Connector (98).
ACCESSORIES 9-7
VOLTAGE CHECK - MODULE CONNECTED
TEST
TERMINAL
v,
v2
V3
V,
V5
L
B
Vs
SPECIFIED
VOLTAGE TO
GROUND
FUNCTION
Brake Input
Cruise On-Off
Input
Resume/Accel
Input
Set/Coast
Input
Cruise Lamp
Speed
Signal
12V
OV
12V
OV
12V
OV
OV
..........................
..........................
..........................
..........................
..........................
..........................
..........................
12V ..........................
OV ..........................
12V ..........................
Greater than
4V High,
Near OV Low
CONDITIONS
Brake/Clutch Not Applied

Brake/Clutch Applied
Slider Switch On
Slider Switch Off, Set/Coast Depressed or Normal
Slider Switch in Ft/A Position
Slide Switch On, Set/Coast Depressed or Normal
Slider Switch Off, Set/Coast
Depressed or Normal
Slider Switch On, Set/Coast Depressed
Slider Switch Off, Set/Coast Normal
Cruise Engaged
Drive Wheels Rotating on
Applications Listed
RESISTANCE CHECK - MODULE DISCONNECTED

TEST
Re
r,
R3
R<
TERMINAL
C to
Ground
F to H
Fto
Ground
H to
Ground
Kto
Ground
J to
Ground
SPECIFIED
RESISTANCE
FUNCTION
CONDITIONS
Vent Valve
Control
SPS High,
30-55 ....................
Open Circuit ............
15-25 ....................
Measured to Ground, Servo Connected

Measured to Ground, Servo Disconnected
Measured F to H, Servo Connected
SPS Low
Measured F and H to Ground,

Servo Disconnected
Vacuum Valve
Control
30-55 ....................
Measured to Ground, Servo Connected

Measured to Ground, Servo Disconnected
Ground
.........................
Measured to Vehicle Ground
F-02424
Figure 5Control Module Validation Test
9-8 ACCESSORIES
S E R V O C O N N E C T O R D IS C O N N E C T E D
M E A S U R E AT S E R V O P IN S
PIN
FUNCTION
RESISTANCE
CONDITIONS
D to B
SPS
15 -2 5 n
M E A S U R E D B E T W E E N P IN S D A N D B
(IF M E A S U R E D R E S IS T A N C E IS N O T S T A T E D V A L U E , R E P L A C E S E R V O )
A to C
V E N T VA LV E
3 0 -5 5 n
M E A S U R E D B E T W E E N P IN S A A N D C
E to C
V A C U U M V A LV E
3 0 -5 5 n
M E A S U R E D B E T W E E N P IN S E A N D C
4.
M u lti-m e te r
5.
S e rv o
6.
S e rv o C o n n e c to r
B -0 7 6 4 4
Figure 6~Servo Resistance Measurement

- +
CRUISE CONTROL MODULE

REPLACEMENT
1. M o d u le a s s e m b ly (1 1 6 ).
2.
H a r n e s s c o n n e c to r (1 2 1 ).
1. H a rn e s s c o n n e c to r (1 2 1 ).
2.
M o d u le a s s e m b ly (1 1 6 ) b y p r y in g b a c k t h e r e ta in in g
c lip o n t h e b r a c k e t a n d s lid in g t h e m o d u le o u t.
Test
1
Action
A p p ly
C (A -C
1 2 v o lts to A
an d
Reaction
E , th e n
g ro u n d
c lo s e s t h e n o r m a lly o p e n v e n t
v a lv e
E -C o p e n s th e n o r m a lly c lo s e d
va c u u m
v a lv e ).
R e m o v e v o lta g e fr o m
S e r v o s h o u ld
u u m
fu ll s tr o k e . If n o t, c h e c k v a c
h o s e s to th e v a c u u m
T h e s e r v o s h o u ld
h o ld
s u p p ly .
a fu ll s t r o k e . If n o t, g o
to th e n e x t s te p . If s e r v o h o ld s , g o to s te p 4 .
D is c o n n e c t th e v a c u u m
th e s e rv o a n d
b r a k e r e le a s e a t
p lu g t h e s e r v o . M o m e n t a r
ily a p p ly 1 2 v o lt s t o
E to a llo w
th e s e rv o
If t h e s e r v o h o ld s its p o s it io n , a d ju s t t h e
b ra k e v a c u u m
r e le a s e v a lv e o r r e p la c e th e
v a lv e . S e e O n - V e h ic le S e n /ic e in t h is s e c t io n .
to fu ll s tr o k e .
4
T u rn
Ig n itio n
O N
V acu u m
T u rn
Ig n itio n
O F F a n d d is c o n n e c t
W ith
vacu u m
T u rn
v a lv e c o n n e c t o r a t t h e v a lv e .
Ig n itio n
O N .
r e le a s e v a lv e s h o u ld
a p r o p e r ly a d ju s te d
b a tte r y v o lta g e s h o u ld
e n g a g e .
b ra k e s w itc h ,
b e p re s e n t a c ro s s
t h e (2 ) c o n n e c t o r t e r m in a ls . N o
v o lta g e
in d ic a te s a n o p e n
b a tte ry
c ir c u it.
F -0 2 4 3 6
Figure 7Vacuum Servo Test
ACCESSORIES 9-9
SET/COAST
(S/C) SW
POSITION
SLIDER
1-2
C-B
1-3
C-D
1-4
C-A
2-3
B-D
2-4
B-A
3-4
D-A
Normal
Normal
Normal
Depressed
Depressed
Depressed
Off
On
R/A
Off
On
R/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
c
c
C Closed
0 Open
A .
B lu e
B.
G re e n
C.
Y e llo w
D.
R ed
F -0 2 4 3 7
Figure 8Mode Control Test
11.
V a c u u m
12.
R e ta in e r
13.
S to p
14.
B ra k e
R e le a s e V a lv e A s s e m b ly (M a n u a l T r a n s m is s io n )
L a m p S w itc h
P ed al
Figure 9Vacuum Release Valve
F -0 2 4 3 5
9-10 ACCESSORIES
116. M odule
117. Nut (2.8-4.0 N-m)
118 Bolt/Screw
120. Convenience Pack Bracket

121. Cruise C ontrol Harness
122. Park Brake ASM
F -0 2 2 6 0
Figure 10Clutch Release Switch
MULTI-FUNCTION SWITCH
REPLACEMENT
1. P ro te c to r c o v e r (2 6 ).
2.
+ -
1. C r u is e c o n tr o l w ir e (2 7 ) w ith t h e u s e o f a p ia n o w ir e .
2.
M u lti-fu n c tio n s w itc h (2 4 ).
3. P ro te c to r c o v e r (2 6 ).
M u lti-fu n c tio n s w itc h (2 4 ).
3 . C r u is e c o n tr o l w ir e (2 7 ).
G TRU CK
99.
100.
101.
102.
C lutch Release S w itch

C lutch
Brake Pedal Bracket
R etainer
102
100
R V -T R U C K
F -0 2 2 6 1
Figure 11Controller Module Mounting
ACCESSORIES 9-11
Figure 12Multi-Function Lever Replacement

SERVO REPLACEMENT
1. S e rv o (3 5 ).

1. V a c u u m h o s e s (3 9 ) a n d h o s e a s s e m b ly (4 9 ).
2 . R e ta in e r (3 4 ).
3. R o d (3 3 ).
4 . C r u is e c a b le a s s e m b ly (5 0 ) (fig u r e 1 6 ).
5.
2.
B o lts (3 6 ) .
Ig n itio n a n d f a s t id le c a m s h o u ld b e
t h r o ttle s h o u ld b e fu lly c lo s e d b e f o r e
th e
th e
a d ju s tm e n t p r o c e d u r e .
3 . C r u is e c a b le a s s e m b ly (5 0 ).
4 . R o d (3 3 ).
B o lts ( 3 6 ) a n d s e r v o (3 5 ) .
NOTICE: Flexible components (hoses, wires,

con du its, e tc .) m ust not be ro u te d w ithin
50 m m (2 in c h e s ) o f m o ving parts o f the
a c c e le ra to r lin k a g e fo rw a rd o f the servo
a s s e m b ly u n le s s ro u tin g is p o s itiv e ly
controlled.
o ff a n d
s ta r tin g
Adjust
R o d ( 3 3 ) s o t h a t it a s s e m b l e s o v e r s t u d ( 3 2 )
(fig u r e 1 4 ).
C r u is e c a b le a s s e m b ly ( 5 0 ) to t h e th ir d b a ll o n
t h e s e r v o c h a in (fig u r e 1 6 ).
J a m n u t ( 5 3 ) u n til t h e c a b le s le e v e a t t h e
t h r o t t le le v e r is t ig h t b u t n o t h o ld in g t h e t h r o t t le
o p e n (fig u r e 1 6 ).
R e ta in e r (3 4 ).
V a c u u m h o s e s (3 9 ) a n d h o s e a s s e m b ly (4 9 ). R e fe r
to fig u r e s 1 7 th r o u g h 2 0 fo r h o s e r o u tin g s .
9-12 ACCESSORIES
A.
1.0-0.5 mm
VIEW A
G VAN
VIEW A
B.
0.2-.04 mm
30.
VIEW A
C-K TRUCK
N u t
31.
L ever
32.
S tu d
33.
R od
34.
R e ta in e r
35.
S e rv o
36.
B o lt
3 7 . B ra c k e t
56. Tab
A .
0 .5 -i.0 m m
(0 .1 9 -0 .3 9 -in c h e s )
B.
0 .2 -0 .4 m m
( .0 0 7 8 7 - .0 1 5 7 5 -in c h e s )
VIEW
F -0 2 2 5 8
F ig u r e 1 3 S e r v o M o u n tin g ( V 6 G a s )
30.
N u t
31.
L ever
32.
S tu d
33.
R od
34.
R e ta in e r
35.
S e rv o
36.
B o lt
37.
B ra c k e t
F -0 2 2 5 9
Figure 14Servo Mounting (V8 Gas)
ACCESSORIES 9-13
F ig u r e 1 5 S e r v o M o u n tin g (R V D ie s e l)
34.
35.
37.
48.
49.
50.
51.
52.
53.
Retainer
Servo
Bracket
A ccelerator Cable
Hose A ssem bly
Cruise Cable A ssem bly
Radiator S upport
C lips
Jam N uts
VIEW B
Figure 16Servo Mounting (G-Van Diesel)
9-14 ACCESSORIES
55 4?
VIEW A
35.
S e rv o
39.
V acu u m
42.
F ittin g
44.
V acu u m
45.
A /C
49.
S e rv o
52.
S tra p
55.
C h e c k V a lv e
H o s e
T ank
V acu u m
H o se
H o s e A s s e m b ly
F -0 2 2 5 5
Figure 17Vacuum Hose Routing (RV-Truck V6)
35.
S e rv o
39.
V acu u m
H o se
44.
V acu u m
T ank
45.
A /C
46.
C ap
V acu u m
H o se
49.
S e rv o
52.
S tra p
53.
O il F ill T u b e
54.
V a c u u m
VIEW B
H o s e A s s e m b ly
F ittin g
^
F -0 2 2 5 4
Figure 18Vacuum Hose Routing (G-Van V6)
ACCESSORIES 9-15
35.
39.
44.
45.
46.
52.
54.
55.
S e rv o
Vacuum Hose
Vacuum Tank
A/C Vacuum Hose
Cap
Strap
Vacuum F itting
Check Valve
39
F -0 2 4 0 0
F ig u r e 1 9 V a c u u m
H o s e R o u tin g R V - T r u c k (V 8 G a s )
Figure 20Vacuum Hose Routing G-Van (V8 Gas)
9-16 ACCESSORIES
RADIO
DESCRIPTION
F o r o p e r a tio n o f th e fa c to r y in s ta lle d s ta n d a r d a n d
o p t i o n a l r a d i o s a v a i l a b l e , r e f e r t o t h e O w n e r s M a n u a l o r
r a d io s u p p le m e n t s u p p lie d w ith th e v e h ic le .
T h e r e c e i v e r is m o u n t e d u s in g t h e f r o n t s u p p o r t t u b e s
s u rr o u n d in g th e c o n tro l s h a fts , a n d a r e a r s u p p o rt
b r a c k e t. T h e fr o n t s u p p o r t t u b e s a r e s e c u r e d w ith n u ts .
T h e r e a r s u p p o r t b r a c k e t is s e c u r e d w it h a s c r e w .
T h e p o w e r , a n t e n n a , a n d s p e a k e r h a r n e s s e s c o n n e c t to
th e r e a r o f t h e r e c e iv e r.
D e p e n d in g o n th e
m o u n te d a t th e c e n te r
p a n e l s o r in t h e r e a r c o
T h e a n te n n a m a y b e
t h e r ig h t f r o n t c o r n e r o f
s y s te m , th e s p e a k e rs c a n b e
o r e n d o f t h e d a s h , in t h e s id e
rn e rs o f th e c a b .
m o u n t e d in t h e w in d s h ie ld , o r o n
th e v e h ic le .
DIAGNOSIS
ACCESSORY NOISE
S in c e r a d io p r o b le m s a r e m o s t o fte n r e p a ir e d a t a u th o r
iz e d w a r r a n t y r e p a ir s t a t io n s , t h e t e n d e n c y is to r e m o v e
t h e s e t w h e n a p r o b le m is r e p o r t e d , w it h o u t a n y p r e lim i
n a r y d ia g n o s i s . T h i s r e s u lt s in a l a r g e n u m b e r o f r a d io s
s h o w in g u p a s N O T R O U B L E F O U N D u n its w h e n r e
c e iv e d b y th e w a r r a n ty r e p a ir s ta tio n s . M a n y tim e s , w h e n
t h is is t h e c a s e , t h e t r o u b le u s u a lly c o u ld h a v e b e e n c o r
o n e e n d to t h e b lo w e r m o to r a n d t h e o th e r e n d to t h e h o t
le a d f r o m t h e b lo w e r m o t o r s w it c h . A ls o , g r o u n d t h e
r e c te d w ith o u t r e m o v a l o f th e r a d io , s u c h a s n o is e c o m
c a p a c ito r g ro u n d ta b .
BLOWER MOTOR NOISE (Figure 32)

In s ta ll a
b lo w e r m o to r fe e d
th ro u g h
c a p a c ito r . A tta c h
p la in t s .
T h e in c o n v e n ie n c e o f d r iv in g w ith o u t a r a d io , w h ile th e
s e t is b e in g s e r v ic e d a t a w a r r a n t y r e p a ir s t a t io n , c a n f r e
q u e n t l y b e a v o id e d if t h e f o ll o w in g q u i c k c h e c k s a r e u s e d
to e lim in a te e x te r n a l r a d io s y s te m p r o b le m s b e fo r e r e m o v
in g th e r a d io fo r r e p a ir :
BLOWER SWITCH POP (HIGH SETTING TO OFF)

In s ta ll a d io d e ( d io d e n u m b e r IN 4 0 0 1 , o r t h e e q u iv a le n t
d io d e to w ith s ta n d a 5 0 V in v e r s e p e a k v o lta g e ) fr o m th e
h ig h s p e e d s w it c h w ir e ( o r a n g e ) to g r o u n d o n t h e h ig h
s p e e d b lo w e r r e la y u n d e r t h e h o o d .
T e s t th e r a d io s o u ts id e , w ith th e h o o d d o w n .
BRAKE SWITCH POP
M o s t n o is e c a n
In s ta ll a 0 .5 M F D c a p a c it o r b e t w e e n th e tw o w ir e s g o in g
to t h e b r a k e s w it c h a t t h e b r a k e p e d a l. A ls o , in s t a ll a 0 .5
M F D c a p a c ito r fr o m th e 1 4 V le a d to g r o u n d a t th e b r a k e
b e fo u n d
on w eak
A M s ta tio n s
n e a r t h e lo w f r e q u e n c y a n d e n d o f t h e b a n d
Ig n itio n n o is e o n F M
s y s te m .
in d ic a te s a p o s s ib le f a u lty H E I
If a t e s t a n t e n n a is u s e d , g r o u n d t h e b a s e t o t h e c a r
body and D O N O T H O LD T H E M A ST.
9 0 %
o f th e n o is e s e n te r v ia th e a n te n n a .
A s m a ll a m o u n t o f ig n itio n n o is e m a y b e n o r m a l
w h e n t h e H E I is lo c a t e d n e a r t h e c o w l ( w in d s h ie ld
a n t e n n a s o n ly ).
C o a te d s c r e w s o r b o lts C A N
W in d s h ie ld
a c t a s a p o o r g ro u n d .
a n te n n a s a r e m o r e p r o n e to n o is e a n d
s t a t io n d ir e c tiv ity .
CLICKING OR POPPING NOISE (DIESEL ENGINE)

1 ) T h e p r o b le m w ill s o u n d s im ila r to ig n it io n n o is e .
H o w e v e r , i t w o n t v a r y w i t h e n g i n e s p e e d . A l s o t h e
n o i s e w ill m o s t lik e ly b e n o t i c e a b le o n l y in t h e id le
c o n d itio n .
2 ) T h e n o is e is b e in g g e n e r a t e d b y t h e h ig h v a c u u m
s w it c h in t h e E G R a s s e m b l y ( f i g u r e 3 4 ) .
3 ) C h e c k th e s y s te m
4 ) If t h e
fo r a n y v a c u u m
le a k s a n d r e p a ir .
n o i s e s till r e m a i n s , c h a n g e t h e
E G R
c o n tro l
a s s e m b ly .
M o s t h o s e s a r e c o n d u c t iv e u n le s s t h e y h a v e a w h ite
CRUISE CONTROL POP (TRANSDUCER TYPE)
s tr ip e .
F o r c r u is e c o n tr o l e n g a g e a n d d is e n g a g e p o p s , in s ta ll a
0 .5 M F D c a p a c it o r fr o m t h e h o ld lin e a t t h e t r a n s d u c e r to
W h e n s h ie l d in g t h e d a s h , w ir e , h o s e , e t c ., u s e fo il o r
s c r e e n a n d g r o u n d it.
s w itc h .
W e a k o r f a d in g A M is o f t e n c a u s e d b y i m p r o p e r ly
a d ju s te d a n t e n n a t r im m e r (w h e n p r e s e n t).
A lw a y s
a s a n a id
in te r m itte
o r r u n n in
d e te r m in e th e e x a c t n a
to d ia g n o s is . K n o w in g
n t o r c o n s ta n t, w h e th e r
g , a n d w h e t h e r it o c c u
tu r e o f th e r a d io p r o b le m
w h e t h e r t h e c o n d i t i o n is
it o c c u r s w i t h e n g i n e o f f
r s w ith c a r s ta tio n a r y o r
m o v in g , w ill h e lp to p in p o in t t h e p r o b le m . U s e C h a r t 1 to
is o la te r a d io p r o b le m s , t h e n p r o c e e d to th e d ia g n o s tic
c h a rts .
g r o u n d . If d is e n g a g e p o p s a r e s till p r e s e n t , s p lic e a 0 .5
M F D c a p a c ito r a c r o s s th e c o n ta c ts o f th e d is e n g a g e
s w itc h a t th e b r a k e p e d a l.
HORN BLOW-THRU NOISE OR HASH (STATIC IN

RADIO SPEAKERS WHEN USING HORN)
S p lic e b lo w e r m o to r c a p a c it o r s in to
th e c a p a c ito r s a s c lo s e to th e h o r n a s
th e c a s e o f th e c a p a c ito r to c h a s s is
m e ta l g r o u n d ta b o n th e c a p a c ito r . T h e
s o ld e r a ll c o n n e c t io n s in s t e a d o f u s in g
e a c h le a d . In s ta ll
p o s s ib le . G r o u n d
g r o u n d u s in g t h e
t e c h n ic ia n s h o u ld
q u ic k c o n n e c ts .
ACCESSORIES 9-17
B-06920
Figure 21Chart 1 (System Diagnosis & Analysis)
9-18 ACCESSORIES
B-06921
Figure 22Chart 2 (Noisy Part 1)
ACCESSORIES 9-19
B-06922
Figure 23Chart 3 (Noisy Part 2)
9-20 ACCESSORIES
Try the fo llo w in g fix e s in

the given o rd e r
1. Install 1224205 filte r
p a ck a g e s on BOTH
th e battery and ig n i
tio n pow er leads to
th e d ig it a l d a s h .
These should be tried
w ith and w ith o u t the
1224205s black lead
a tta c h e d to ground,
to determ ine best re
sults. Also, the black
w ire o f th e filte r pack
age m ust face away
from the dash.
2. Install one-piece an
tenna lead-in and run
a b r a id e d g r o u n d
strap from the base
o f the antenna to the
negative battery te r
m inal.
Try the fo llo w in g fixe s in

the given order.
1. Install a 1224205 filte r
package to the ig n i
tio n pow er line (pink
and black wire) o f the
ECM. The black w ire
o f the filte r package
s h o u ld fa c e a w a y
fro m th e ECM. The
filte r should be tried
w ith the filte rs black
le a d g ro u n d e d and
ungrounded to de te r
m in e b e s t re s u lts .
The black w ire o f the
filte r m ust face away
from the ECM.
2. Install a 1224205 filte r
package to the m em
ory lead (orange wire,
te r m in a l R) o f th e
ECM. Again, face the
b la c k w ir e o f th e
1224205 aw ay fro m
the ECM.
B-06923
Figure 24Chart 4 (ECM or Digital Dash Noise)
ACCESSORIES 9-21
CHART 5
IGNITION NOISE
D eterm ine the source of
the ig n itio n noise.
1 o r 2 cylinders.
A ll cylinders.
-
Try th e fo llo w in g fixe s in

the given order:
1. C h e ck fo r lo o s e o r
defective spark plug
wire.
2. R eroute s p a rk plu g
w ires laying a gainst
a n y th in g th a t c o u ld
p o s s ib ly tr a n s m it
n o is e to th e ra d io
( w ir in g o r s e n s o r
leads th a t travel into
the passenger c o m
partm ent).
3. C heck fo r
f a u lt y
spark plug.
4. R e pla ce d is tr ib u to r
cap and rotor.
'
Try the fo llo w in g fixes in

the given order:
1. C h e c k th e g ro u n d
from engine to bulk
head;
in s t a ll
a
braided ground strap
if necessary.
2. I n s t a ll a b ra id e d
ground strap on the
hood.
3. C h e c k h e a te r c o re
ground; clean or in
stall braided ground
strap if necessary.
4. C heck air co n d itio n e r
accu m u la to r ground;
c le a n o r in s t a ll a
braided ground strap
if necessary.
5. Move all w irin g away
from HEI and spark
plug wires.
6. In s p e c t HEI fo r the
fo llo w in g and replace
if necessary:
D is t r ib u t o r c a p
c a rb o n
b a ll
eroded away, o r
cracked or loose
cap.
A
r o to r
w ith
b u rn e d
b la c k
spot on w ip e r o r
p its in w ip e r sur
face.
A fa u lty coil.
A n o ily film on
som e of the lead
te rm in a ls o r in
side the cap.
Faulty HEI m od
ule; can cause ig
n itio n n o is e on
FM only.
B-06924
Figure 25Chart 5 (Ignition Noise)
9-22 ACCESSORIES
CHART 6
ANTENNA NOISE - PART 1
W in dsh ie d antenna
Noise elim inated.
Plua antenna back into the radio.
Place alum inum fo il

over the entire dash
to p and g ro u n d it
w ith c lip le ads to
each d o o r and jam
s w itc h .
Noise remains
Use a s n iffe r to lo
c a te fro m w h ic h
part o f the dash the
n o is e
is
b e in g
generated.
A fte r lo c a tin g th e
a re a o f th e d a s h
where the noise is
b e in g g e n e r a te d ,
th e fo llo w in g fix e s
are possible.
U np lug a n ten n a at
the cow l.
N oise elim inated.

C heck the m o unting
(g ro u n d ) c o n n e c
tio n s o f th e c o w l
s h ie ld . It m u s t be
grounded.
G ro u n d th e h o o d
w ith a short ground
strap from the cow l.
(Scrape the surface
around th e m o u n t
ing holes fo r good
contact).
N oise rem ains
Suppress the noise
at the source using
th e
a p p r o p r ia te
c h a r t:
IG N IT IO N
NO ISE, A LT E R N A
TOR W H IN E , A C
CESSORY NOISE.
Line the underside

o f the dash w ith alum in u m ta p e , th e
ta p e
M UST
BE
GROUNDED.
N oise remains.
If a n o isy w ire or
c a b le c a n be lo
cated w it the sniffer,
re-route it o r ground
th e s h ie ld o f any
n o isy cable.
M e a s u re
g ro u n d
from lead-in shield
(at radio end o f leadGood ground.
in) to good ground,
Less than
usin g low est scale
on a d ig ita l ohm m e- 0.2 Ohm s
ter.
G re a te r th a n 0.2
O hm s
C heck antenna leadin screw s at cow l.
Scrape area and in
stall sh in y screw s
to in s u re a g o o d
ground.
--------
-----------
A g a in
m e a s u re
ground from the an
tenna lead-in shield
to a good ground.
iG r e a te r
R e p la c e th e antenna lead-in.
If all else fails, in

s ta llin g an o u ts id e
a n te n n a w ill o fte n
e lim in a te th e c u s
to m e rs com plaint.
Less than
0.2 O hm s
han
0 .2 O hm s
N oise rem ains.
S uppress the noise

at the source using
th e
a p p r o p r ia te
c h a r t:
IG N IT IO N
N O IS E , A LT E R N A
TOR W H IN E , A C
CESSORY NOISE.
B-06925
Figure 26Chart 6 (Antenna Noise Part 1)
ACCESSORIES 9-23
B-06926
Figure 27Chart 7 (Antenna Noise Part 2)
9-24 ACCESSORIES
CHART 8
WEAK
[only
AM and FM weak or
o n ly AM is weak.
Com pare the FM re

c e p tio n to a n o th e r
car w ith an FM ra
d io . T u n e in t o a
weak station.
Trim the A n te n n a 1
See P rocedure Be
low
W ont trim
1 weak.
Check the antenna
system w ith a test
antenna.
Radio
W orks
STOP
FM is weak
o r s till
C u s to m e r s ra d io
h a s c o n s id e r a b ly
weaker reception.
Both radios have rel

a tiv e ly s im ila r re
ce p tio n capabilities.
S till Weak
Return to Norm al
Remove t ie Radio
Remove the Radio.
Repair the antenna

system . Retrim .
Explain to the cu s
to m e r that the radio
is norm al.
*ETR and 2000 series radios do not have an an

tenna trim m er. Try a s u b s titu te antenna.
ANTENNA TRIMMER ADJUSTMENT

The antenna trim m e r adju stm e nt m atches the
antenna c o il in the radio to the antenna. Only
AM radios, o r the AM part o f AM /FM radios,
need th is a d justm e n t. (ETR m odels and all 2000
series radios use se lf a d ju s tin g circu its, and
do not have an antenna trim m er).
1. Tune the radio to a weak AM sta tio n o r noise
near 1400 kHz. Turn the volum e all the way
up. You sho u ld barely hear the station.
2. Remove the rig ht inner and oute r knobs.
3. Use a sm all screw driver to ad just the trim
m er screw. A d ju s t the screw fo r the loudest
volum e.
4. R einstall th e c o n tro l knobs.
B-06927
Figure 28Chart 8 (Weak)
ACCESSORIES 9-25
Try th e f o llo w in g
fixes in the given o r
der:
1. I n s t a ll a 250
MFD, 100V capa
c ito r on the al
te rn a to r o u tp u t
lead and/or th e
brown fie ld w ire
o f the a lterna tor
to ground.
2. Exchange radio
w it h a k n o w n
g o o d ra d io . If
th is e lim in a te s
the noise, send
the fa u lty radio
to an authorized
repair shop.
3. D e d i c a t e d
g ro u n d fo r th e
ra d io re c e iv e r.
C u t th e b la c k
w ire o f the black
plug in back of
the radio. A ttach
a
b ra id e d
g ro u n d
s tr a p
from the case o f
th e ra d io to a
g o o d c h a s s is .
Try th e f o llo w in g
fixe s in the given or
der:
1. I n s t a ll a 250
MFD, 100V capa
c ito r on the al
te rn a to r o u tp u t
lead and/or the
brown fie ld w ire
at the alternator.
2. Install a 1224205
filte r p a cka g e
on the e x is tin g
ground w ire fo r
the radio.
3. E x c h a n g e th e
ra d io w ith
a
know n good ra
dio. If th is e lim i
nates the noise,
send the fa u lty
ra d io
to
an
a u th o r iz e d re
pair shop.
4. Replace the a l
ternator.
4. Run a w ire d i
re c tly fro m the
p o sitive ba ttery
te rm in a l to the
alternator.
5. Replace the a l
ternator.
B-06928
Figure 29Chart 9 (Alternator Whine)
9-26 ACCESSORIES
CHART 10
DEAD I
C h e c k th e ra d io .
Check to see if all
speakers are dead.
(Use fader to check.)
Test the speakers.
A ll m odes are dead.
U sing an ohmmeter,
m easure from all 8
speaker term inals of
b lu e
and
w h ite
p lugs at the back of
radio, to ground.
O n e o r m o re
A ll open
shorted
Check the radio 14V

at ca vity F on the
black plug of the ra
dio. Also, check for
14V on the orange
wire o f the m em ory
c o n n e c to r on th e
back of radio. Also,
c h e ck the speaker
co n n e ctio n s at the
w h ite
an d
b lu e
plugs on the back of
the radio. Refer to
diagram below).
M e a s u re
a c ro s s
each speaker (A-C,
B-D, etc.)
ot open
or Shorted
R e p a ir o r re p la c e
h a rn e s s . R e c h e c k
radio.
I Open o r Shorted
Replace
speaker or
repair
co n ne ctio n.
Remove
radio.
Not O K I
Remove
radio.
OK
STOP
Bad
.r
AM and FM dead or
AM only dead.
C heck antenna and

lead-in w ith a sub
s titu te
a n te n n a .
Bad
Repair the connection.
C o rre c t th e p ro b lem.
Radio W orks
Radio W orks
No Reception
Remove the rad io.
S top.
R e p la c e
th e
m a lfu n c tio n in g antenna or lead-in. Retrim .
*W hen radio has been determ ined

to be defective, be sure to describe
the sym p tom s to aid th e radio te c h
nician.
Remove radio
Check all the acces

sories on the fuse
fo r the problem . Re
fe r
to
S e rv ic e
Manual. Test drive if
necessary).
C heck the antenna

co n ne ctio n.
U n p lu g th e ra d io
pow er lead. Replace
the fuse.
G o o d
Repair
G ood
Check the fuse. I

F u s e Blown
Fuse
Fuse Blows
A gain
Fuse
Doesnt
Blow
P lu g
th e
ra d io
pow er lead back in.
F use
B lo w s
Remove the radio.
FM only is dead.
I Remove the unit.
Front and rear speaker harnesses,

and p o w e r p lu g c o n n e c to r pin
____________ ________|
views.
+ 14V ANT.
F
BLACK
G
trt
FDIMMER
R.F.
WHITE
Figure 30Chart 10 (Dead)
BLUE
L.R.
B-06929
ACCESSORIES 9-27
*NOTE: Jam m ed tape cannot be removed from

th e search and repeat tape deck. Send the radio
to authorized repair shop.
CAPSTAN
CLEANING PARTS OF TAPE PLAYER

TO REDUCE TAPE NOISE
There are tw o parts th a t you clean on a tape
player; the head and the capstan. S ince you can
reach them through the tape door, you can leave
the tape player in the car.
To clean the head and capstan, use a co tto n swab
dipped in ordinary rubbing alcohol. W ipe the head
and capstan as show n.
B-06930
Figure 31Chart 11 (Tape)
9-28 ACCESSORIES
HORN SWITCH POPS (Figure 36 and 37)

1 ) In s ta ll a 0 .5 M F D c a p a c it o r b e t w e e n t h e s w itc h e d 1 4
v o lt le a d a n d h o r n le a d a t t h e h o r n d e la y .
2 ) If p o p p e r s i s t s , i n s t a ll a 0 .5 M F D c a p a c i t o r f r o m t h e
s w it c h e d 1 4 v o lt le a d o f t h e h o r n r e la y to g r o u n d a n d
a 0 .5 M F D c a p a c it o r fr o m th e h o r n le a d to g r o u n d .
e n g in e s p e e d . A ls o th is n o is e s h o u ld b e n o t ic e a b le w ith
t h e i g n i t i o n o n , a n d e n g i n e o f f , b u t n o t in
a c c e s s o r y p o s itio n .
P r o b le m :
N o is e is b e in g r a d i a t e d f r o m t h e m ix t u r e
s o le n o id d u ty c y c le le a d to t h e A L D L c o n n e c to r .
c o n tro l
MIXTURE CONTROL SOLENOID POPPING
F ix :
C o m p la in t:
A p o p p in g n o is e w h ic h s o u n d s lik e ig n it io n n o is e
o c c u r i n g o n t h e A M b a n d . T h i s n o is e w ill N O T v a r y w it h
1 ) L o c a t e d th e b r e a k o u t h a r n e s s e x te n d in g fr o m th e
m a in h a r n e s s , a b o u t s ix in c h e s fr o m t h e E C M
h a rn e s s c o n n e c to r.
2 ) L o c a t e d t h e lig h t b lu e w ir e . It s h o u ld c o n n e c t to P in
D o n t h e 1 5 p in b r e a k o u t c o n n e c t o r .
3 ) C u t t h e lig h t b lu e w ir e o n t h e v e h ic le
c o n n e c to r a t th e c o n n e c to r.
15
i
Low Vacuum S w itch
S olenoid
EGR A ssem bly
High Vacuum S w itch
B -0 6 9 9 0
Figure 34Diesel EGR High Vacuum Switch
15.
16.
17.
18.
19.
16
17
\
18
s id e o f th e
19
Lead from the Horn S w itch

.5 MFD Feed through C apacitor
Horn No. 1
.5 MFD Feed through C apacitor
Horn No. 2
Figure 36Horn Capacitor
*
B -0 6 9 9 4
ACCESSORIES 9-29
30
20.
21.
22.
23.
24.
To the horn s w itch (steering colum n)

Horn relay.
Power (fused 14 volts)
.5 MFD ca pa citor
To the horns.
B-06995
Figure 37Horn Switch Capacitor

REAR DEFOGGER NOISE OR HASH
A b r o k e n g r i d in t h e d e f o g g e r in t h e r e a r g la s s m a y
c a u s e a h a s h in t h e r a d i o . R e p a i r i n g t h is b r e a k w ill
e lim i n a t e t h e n o is e . A b r e a k in t h e r e a r d e f o g g e r g r id c a n
b e fo u n d b y to u c h in g e a c h lin e o f t h e g r id w h ile t h e r e a r
d e f o g g e r is o n . T h e c o ld g r id is t h e o n e b r o k e n .
TACHOMETER NOISE
L o c a te th e w ir e fr o m
th e d is tr ib u to r c a p to th e
t a c h o m e t e r a n d s h i e l d t h e w i r e b y w r a p p i n g it w i t h
a lu m in u m ta p e . T h e ta p e m u s t a ls o b e c o n n e c te d to a
g o o d g ro u n d .
TORQUE CONVERTER LOCK-UP NOISE

M o d e l:
D ie s e l E n g in e s
31.
32.
33.
34.
35.
36.
37.
To a Test Terminal
To th e Brake S w itch and Fuse B lock
F ilte r Package. 1224205
4-3 S h ift (M om entary open)
TCC S olenoid
4th Gear S w itch (Closed when engaged)
F ilte r G round W ire
D nQiQo
Figure 38Torque Converter Lock Up Noise

WIPER SWISH WINDSHIELD ANTENNA
T h e s w is h s o u n d e n c o u n te r e d w h
o v e r t h e w i n d s h i e l d a n t e n n a is d u e
b e tw e e n t h e w in d s h ie ld a n d t h e w ip
w in d s h ie ld w ith O p tic le a n o r a d d a
s o a p to th e w a s h e r b o ttle .
e n th e w ip e r s p a s s
to a s ta tic b u ild u p
e r. T ry c le a n in g th e
t a b le s p o o n o f d is h
C o m p la in t:
H ash
o r p o p p in g
n o is e
on
A M
band
a fte r
to rq u e
c o n v e r te r lo c k -u p ( 3 5 - 4 5 m p h ).
F ix :
1 ) In s ta
le a d
pack
le a d
ll a 1 2 2 4 2 0 5 f i lt e r p a c k a g e in s e r ie s w it h g r e e n
o n t h e V R V s w it c h ( s e e t h e i n s t r u c t io n s in f ilt e r
a g e ) . F o r th is a p p lic a t io n , c o n n e c t t h e g r o u n d
in t h e f ilt e r p a c k a g e to t h e b lu e le a d o n t h e
V R V s w itc h , in s te a d o f to g r o u n d .
In s ta ll a c a p a c it o r (0 .5 M F D ) fr o m th e b lu e le a d o n
V R V s w itc h to g r o u n d .
F ix :
2 ) In s ta ll a 2 2 0 M F D c a p a c ito r r a te d a t 5 0 V D C a c r o s s
t h e V R V s w itc h b e t w e e n t h e g r e e n a n d b lu e w ir e s .
OTHER ELECTRIC MOTOR NOISES

WINDOWS, BLOWER MOTORS)
(POWER
In s ta ll a 0 .5 M F D c a p a c it o r r a te d a t 5 0 V D C a c r o s s e a c h
m o to r.
OTHER SWITCH POPS (BLOWER SWITCHES, POWER

LOCKS, POWER MIRROS, PARK - NEUTRAL SWITCH,
POWER WINDOWS, WIPERS, REAR WINDOW
DEFOGGER)
In s ta ll a 0 .5 M F D c a p a c it o r r a te d a t 5 0 V D C
c o n ta c ts o f th e s w itc h , fr o m
g ro u n d o r b o th .
a c ro s s th e
th e h o t s id e o f th e s w itc h to
9-30 ACCESSORIES
40
42
/
41
/
_ fn
Ii/ ------ /1--------
p lu g g
used
P ro
1.
e d i n t o t h e r a d i o s a n t e n n a s o c k e t . I t c a n t h e n b e
to p ro b e a n d s e a r c h o u t H o t S p o ts .
c e d u re :
W h ile lis te n in g to t h e c o m p la in t n o is e , d is c o n n e c t
th e a n t e n n a a n d p lu g t h e s n if f e r in to t h e a n t e n n a
s o c k e t.
2 . T u rn th e r a d io v o lu m e u p .
3 . W h e n s e a r c h in g fo r th e n o is e s o u r c e , k e e p fin g e r s
o f f o f t h e p r o b e , o t h e r w is e e r r o n e o u s r e s u lt s w ill b e
r e c e iv e d .
\
43
40.
41.
A n te n n a L e a d
C e n t e r W ir e
42.
W h ite
43.
50 m m
P la s tic
In
In s u la to r
(2 in .) o f C o a x S h ie ld
R em o ved
B -0 9 1 9 7
Figure 39RF Sniffer
DIAGNOSTIC RF SNIFFER
T h e a n t e n n a s n iffe r c a n b e
r a d io to lo c a te H o t S p o t s w
n o is e in te r fe r e n c e . T h e s e H o t
h a r n e s s e s , in t h e u p p e r p a r t o f
u s e d a lo
h ic h a r e
S p o ts w
th e d a s h
T h e s n i f f e r i s m a d e from an o l d p i e c e o f a n t e n n a l e a d - i n
fr o m a m a s t o r p o w e r a n te n n a . T h e lo n g e r th e le a d -in th e
b e t t e r , s i n c e it w ill m a k e t h e s n i f f e r m o r e f l e x i b l e a s a
d ia g n o s tic to o l.
M a k e t h e s n if f e r a s s h o w n in f i g u r e 3 9 . T h e 5 0 m m ( 2
in c h ) s e c tio n w ith t h e b la c k c o a t in g a n d b r a id e d s h ie ld
s t r ip p e d b a c k b e c o m e s t h e a n t e n n a w h e n t h e s n if f e r is
n g w i t h t h e c a r s
g e n e r a tin g r a d io
ill b e f o u n d in t h e
o r e v e n b e tw e e n
th e h o o d a n d w in d s h ie ld .
W h e n c h e c k in g
b e a c h ie v e d w h e n
T h e s n iffe r c a n
a re a o f th e d a s h
w in d s h ie ld a n t e n n
fo r n o is e o n a
t h e s n if f e r is p
a ls o b e u s e d
t h e n o i s e is
a.
w ir e , t h e b e s t r e s u lt s w ill
la c e d p a r a lle l to th e w ir e .
to d e te r m in e fr o m w h a t
b e in g g e n e r a te d o n to a
T h e s n iffe r c a n a ls o b e u s e d to lo c a te H o t S p o t s
b e tw e e n th e w in d s h ie ld a n d th e h o o d t h a t m a y b e
d ir e c tin g n o is e o n to th e w in d s h ie ld a n t e n n a .
It m u s t b e n o t e d t h a t t h e s n if f e r w ill a l s o lo c a t e
n o r m a l h o t s p o ts . H o w e v e r , th e te c h n ic ia n w h o
b e c o m e s f a m i l i a r w i t h t h e s n i f f e r s c a p a b i l i t i e s w i l l f i n d it
t h e m o s t u s e f u l d ia g n o s t ic t o o l in n o is e s u p p r e s s io n w o r k .
RADIO RECEIVER REPLACEMENT

RV MODELS
2.
3.
4.
5.
6.
*+ Remove or Disconnect (Figure 40)

1. B a t t e r y g r o u n d c a b l e
S
N
K
C
B
u
u
n
o
a
p p o rt b ra c k e t s c re w s (5 5 )
ts (5 2 ) o n th e s u p p o rt tu b e s (5 1 )
o b b e z e ls (5 3 )
n tro l k n o b s (5 4 )
tte r y g r o u n d c a b le
2. C o n t r o l k n o b s ( 5 4 )
G VAN
3 . K n o b b e z e ls (5 3 )
4 . N u ts (5 2 ) fro m th e s u p p o rt tu b e s (5 1 )
5 . S u p p o r t b r a c k e t r e ta in e r s c r e w s (5 5 )
6. H a r n e s s e s
L ift u p t h e r e a r e d g e o f t h e r e c e iv e r .
P u s h t h e r e c e iv e r fo r w a r d u n til t h e
s h a fts c le a r th e in s tr u m e n t p a n e l.
L o w e r th e c o n tro l s h a fts .
c o n tro l
R e m o v e th e p o w e r fe e d , s p e a k e r a n d a n te n n a
c o n n e c to rs .
R e c e iv e r (5 0 )
R e c e iv e r (5 0 )
P o s itio n
p a n e l.
C o n n e c t th e p o w e r, s p e a k e r a n d a n te n n a
le a d s .
L ift t h e r e a r o f t h e r e c e iv e r in to p la c e .
r e c e iv e r
under
th e
in s tr u m e n t
M o v e th e r e c e iv e r r e a rw a rd s o th a t th e c o n tro l
s h a f t s s l id e t h r o u g h t h e c o n t r o l s h a f t h o l e s in
th e in s tr u m e n t p a n e l.
3 . A ir c le a n e r c o v e r
4 . A ir c le a n e r e le m e n t
5. C o n tro l k n o b s (5 4 )
6. K n o b b e z e l s ( 5 3 )
7. R e ta in in g n u ts (5 2 )
8. R e a r m o u n t i n g b r a c k e t s c r e w s ( 5 5 )

th e
1. B a t t e r y g r o u n d c a b l e
2. E n g i n e c o v e r
9 . P o w e r, s p e a k e r a n d a n te n n a le a d s
P u s h r e c e iv e r fo rw a rd .
L o w e r r e c e iv e r.
D is c o n n e c t le a d s .
10. R e c e i v e r ( 5 0 )
-
1 . P o w e r , s p e a k e r a n d a n t e n n a le a d s .
2 . R e c e iv e r (5 0 )
R a is e r e c e iv e r in to p la c e .
ACCESSORIES 9-31
A.
B.
50.
51.
52.
53.
54.
55.
G Van
CK Truck
Receiver
Support Tube
Nut
Knob Bezel
Knob
Support Bracket Screw
B-06949
Figure 40Receiver Installation
9-32 ACCESSORIES
M o v e r e c e iv e r r e a r w a r d s o th a t
s h a f t s a r e in t h e m o u n t i n g h o le s .
th e
c o n tro l
3 . R e a r m o u n tin g b r a c k e t s c r e w s (5 5 ).
4 . R e ta in in g n u ts (5 2 ) o n th e s u p p o r tin g tu b e s (5 1 ).
8 . A ir c le a n e r c o v e r.
9 . E n g in e c o v e r.
1 0 . B a tte r y g ro u n d c a b le .
NOTICE: Always connect the speaker wiring

harness to the receiver before applying power
to the receiver in order to prevent receiver
damage.
5. K n o b b e z e l (5 3 ).
6. C o n tro l k n o b s (5 4 ).
7. A ir c le a n e r e le m e n t .
ANTENNA REPLACEMENT
+ -
1. W in d o w .
R e fe r
to
S e c .
10
W in d s h ie ld
R e p la c e m e n t .
2 . A n te n n a c a b le c o n n e c to r
3 . B a tte r y g r o u n d c a b le
G VAN
1.
2.
3.
4.
5.
6.
7.
B a tte r y g r o u n d c a b le
M a s t r e t a i n i n g n u t (56)
M a s t (57)
N u t (55)
S e a l (54) a n d b e z e l
S e a l (52)
(53)
B o d y a n d c a b le a s s e m b ly
8. W a s h e r
(50)
(51)
|+<-| Install or Connect
RV MODELS
1. B a tte r y g r o u n d c a b le
2 . A n te n n a c a b le c o n n e c to r
3. W in d o w .
R e fe r
to
S e c .
R e p la c e m e n t .
10
W in d s h ie ld
1.
2.
3.
4.
5.
6.
7.
W a s h e r (51)
B o d y a n d c a b le a s s e m b ly
S e a l (52)
S e a l (54) a n d b e z e l (53)
N u t (55)
M a s t (57)
M a s t r e t a i n i n g n u t (56)
(50)
SPEAKER REPLACEMENT
RV MODELS
1. S p e a k e r h a r n e s s to s p e a k e r (7 1 )
FRONT SPEAKER
2 . S p e a k e r (7 1 )

2 . In s tr u m e n t c lu s te r b e z e l u p p e r fo u r s c r e w s
3 . In s tr u m e n t p a n e l p a d s c r e w s
4. P a d ( 7 0 )
3 . S p e a k e r to d a s h p a n e l s c r e w s (7 2 )
4.
P a d (7 0 )
5 . In s tr u m e n t p a n e l p a d s c r e w s
5 . S p e a k e r to d a s h p a n e l s c r e w s (7 2 )
6. S p e a k e r h a rn e s s
6 . In s tr u m e n t c lu s te r b e z e l u p p e r fo u r s c r e w s
L ift u p s p e a k e r ( 7 1 )
7. S p e a k e r (7 1 )
ACCESSORIES 9-33
Body and Cable A sse m b ly

W asher
Seal
Bezel
Seal
Nut
M ast R etaining Nut
M ast
B-09198
Figure 42Antenna System G-Van
Figure 43Front Speakers RV
ACCESSORIES 9-35
A.
B.
C.
80.
81.
82.
83.
CK Pickup
U tility
Suburban
G rille
Speaker
Speaker M o u n tin g Screw
C lip Nut
84. In su la to r
85. In su la to r
86. Bracket
87. Bracket R etaining Screw
88. Speaker R etaining Screw
89. Trim Panel
90. G rille R etaining Screw
Figure 45Rear Speakers RV

REAR SPEAKER
G VAN

FRONT SPEAKER
2 . G r ill r e ta in in g s c r e w s ( 9 0 )
3 . G r ill ( 8 0 )
4 . S p e a k e r r e ta in in g s c r e w s ( 8 2 )
2.
In s tr u m e n t p a n e l b e z e l
3.
In s tr u m e n t c lu s te r
5. S p e a k e r h a rn e s s fro m th e s p e a k e r (8 1 )
4 . S p e a k e r s c re w s (1 0 2 )
6 . S p e a k e r (8 1 )
1 . S p e a k e r h a r n e s s to th e s p e a k e r
2 . S p e a k e r (8 1 )
3 . S p e a k e r r e ta in in g s c r e w s (8 2 )
5 . S p e a k e r c o n n e c to r (1 0 1 )
6 . S p e a k e r (1 0 0 )

1. S p e a k e r c o n n e c to r (1 0 1 ) to th e s p e a k e r (1 0 0 )
2.
S p e a k e r (1 0 0 )
3. S p e a k e r s c re w s (1 0 2 )
4 . G r ill ( 8 0 )
4.
In s tr u m e n t c lu s te r
5 . G r ill r e ta in in g s c r e w s ( 8 2 )
5 . In s tr u m e n t p a n e l b e z e l
6.
6.
B a tte r y g ro u n d c a b le
B a tte r y g r o u n d c a b le
9-36 ACCESSORIES
REAR CORNER SPEAKER

1. B a t t e r y g r o u n d c a b l e .
2. L o w e r c o r n e r t r i m p a n e l ( 1 1 4 ) .
3.
L o w e r e d g e s c r e w s o f t h e u p p e r c o r n e r tr im
panel
( 110).
4 . T r im s tr ip (1 1 5 ) s c r e w s .
5 . R e a r d o o r u p p e r m o ld in g (1 1 3 ) s c r e w s .
6. U p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) u p p e r s c r e w s .
7. U p p e r c o r n e r tr im p a n e l a s s e m b ly (1 1 0 ).
8. H o r n e s s c o n n e c t o r f r o m t h e s p e a k e r .
9 . In s u la tio n r e ta in in g s c r e w s .
10. I n s u l a t i o n ( 1 1 2 ) .
11 . S p e a k e r r e t a i n i n g s c r e w s .
12. S p e a k e r ( 1 1 1 ) f r o m t h e u p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) .
El
1. S p e a k e r ( 1 1 1 ) t o t h e u p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) .
2. S p e a k e r r e t a in in g s c r e w s .
3 . In s u la tio n (1 1 2 ).
4 . In s lu la tio n r e ta in in g s c r e w s .
5 . H a r n e s s c o n n e c to r to th e s p e a k e r .
6. U p p e r c o r n e r t r i m p a n e l a s s e m b l y ( 1 1 0 ) .
7. U p p e r c o r n e r tr im p a n e l s c r e w s .
8. R e a r d o o r u p p e r m o l d i n g ( 1 1 3 ) s c r e w s .
9 . T r im s tr ip (1 1 5 ).
10. T r i m s t r i p ( 1 1 5 ) s c r e w s .
11 . L o w e r c o r n e r t r i m p a n e l ( 1 1 4 ) .
12. B a t t e r y g r o u n d c a b l e .
REAR SIDE SPEAKER

1. B a tte r y g r o u n d c a b le .
2 . F o u r f o r w a r d lo w e r s c r e w s r e t a in in g t h e r e a r t r im
p a n e l.
P u ll t h e t r im p a n e l o u t to r e a c h t h e s p e a k e r .
110.
111.
112.
113.
114.
115.
Upper Corner Trim Panel

Speaker
Speaker Insulation
Rear Door Upper M olding
Lower C orner Trim Panel
Trim S trip
B.og219
Figure 47Rear Corner Speakers G-Van

3 . H a rn e s s c o n n e c to r fro m
4 . S p e a k e r r e ta in in g n u ts .
5. S p e a k e r.
th e s p e a k e r.

1. S p e a k e r.
2 . S p e a k e r r e ta in in g n u ts .
3 . H a r n e s s c o n n e c to r to th e s p e a k e r .
4 . R e a r tr im p a n e l s c r e w s .
5 . B a tte r y g ro u n d c a b le .
ACCESSORIES 9-37
120. Speaker
121. N ut
122. Harness C o n n e cto r
B -0 9 2 4 7
Figure 48Rear Side Speakers
9-38 ACCESSORIES
Figure 49Speaker Harness G-Van
10A1-1
SECTION 10
BODY
CONTENTS
SUBJECT
PAGE
D o o rs..................................................................................................................................................................10A1-1
Seats................................................................................................................................................................... 10A2-1
Glass................................................................................................................................................................... 10A3-1
Interior Trim ........................................................................................................................................................10A4-1
End Gate..............................................................................................................................................................10A5-1
SECTION 10A1
DOORS
NOTICE: Door lock striker system fasteners are important attaching parts in that they could affect the performance
of vital parts and systems, and/or coulr result in major repair expense. They must be replaced with one o f the same
part num ber or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part o f lesser
of these parts.
CONTENTS
SUBJECT
PAGE
RV Model Side Front D o or...............................................................................................................................10A1- 4

Door And Hinge Replacement.....................................................................................................................10A1- 4
Door Adjustment.......................................................................................................................................... 10A1- 4
Door Trim Panel Replacement.....................................................................................................................10A1- 4
Door Vent/Window Run Channel Assembly Replacement.......................................................................... 10A1- 5
Vent Glass Replacement...............................................................................................................................10A1- 6
Vent Window Adjustment.............................................................................................................................10A1- 7
Door Window Replacement...........................................................................................................................10A1- 7
Inner Window Weatherstrip Replacement..................... ............................................................................ 10A1- 8
Outer Window Weatherstrip Replacement................................................................................................. 10A1- 8
Rear Glass Run Channel Replacement....................................................................................................... 10A1- 8
Window Regulator Replacement................................................................................................................. 10A1- 9
Door Lock Replacement.............................................................................................................................. 10A1-10
Power Door Lock Motor Replacement......................................................................................................... 10A1-10
Door Outside Handle Replacement............................................................................................................. 10A1-11
Door Lock Cylinder Replacement................................................................................................................. 10A1-11
Door Inside Handle Replacement................................................................................................................. 10A1-12
Door Weatherstrip Replacement................................................................................................................. 10A1-12
Outside Rear View Mirror Replacement....................................................................................................... 10A1-13
Below Eyeline Outside Rear View Mirror Replacement.............................................................................. 10A1-13
West Coast Outside Rear View Mirror Replacement..................................................................................10A1-13
Door Air Valve Replacement.........................................................................................................................10A1-13
RV Model Side Rear Doors..............................................................................................................................10A1-14
Door And Hinge Replacement.....................................................................................................................10A1-14
Door Adjustment.......................................................................................................................................... 10A1-15
Door Trim Panel Replacement.....................................................................................................................10A1-16
10A1-2 DOORS
SUBJECT
PAGE
RV Model Side Rear Doors (Continued)

Stationary Glass/Window Run Channel Assembly Replacement.............................................................. 10A1-16
Door Window Replacement...........................................................................................................................10A1-17
Inner Window Weatherstrip Replacement...................................................................................... ............ 10A1-17
Outer Window Weatherstrip Replacement................................................................................................. 10A1-18
Front Glass Run Channel Replacement....................................................................................................... 10A1-19
Window Regulator Replacement................................................................................................................. 10A1-19
Door Lock Replacement...............................................................................................................................10A1-20
Door Inside Handle Replacement................................................................................................................. 10A1-21
Remote Control Replacement....................................................................................................................... 10A1-21
Door Air Valve Replacement.........................................................................................................................10A1-22
RV Model Rear D oors...................................................................................................................................... 10A1-23
Door And Hinge Replacement..................................................................................................................... 10A1-23
Door Adjustm ent.......................................................................................................................................... 10A1-23
Striker Replacement.....................................................................................................................................10A1-23
Bumper Wedge Replacement...................................................................................................................... 10A1-25
Door Trim Panel Replacement..................................................................................................................... 10A1-25
Window Replacement...................................................................................................................................10A1-25
Right Door Lower Latch Replacement........................................................................................................ 10A1-26
Right Door Upper Latch Replacement......................................................................................................... 10A1-27
Right Door Control Assembly Replacement................................................................................................10A1-28
Left Door Lower Latch Replacement........................................................................................................... 10A1-28
Check Strap Replacement.............................................................................................................................10A1-29
Right Door Weatherstrip Replacement....................................................................................................... 10A1-29
Left Door Weatherstrip Replacement........................................................................................................... 10A1-29
Secondary Weatherstrip Replacement......................................................................................................... 10A1-30
G Model Side Front D o o r.................................................................................................................................10A1-32
Door Trim Panel Replacement..................................................................................................................... 10A1-33
Door Vent/Window Run Channel Assembly Replacement.......................................................................... 10A1-34
Vent Glass Replacement...............................................................................................................................10A1-35
Vent Window Adjustment.............................................................................................................................10A1-36
Door Window Replacement...........................................................................................................................10A1-36
Window Stop Assembly Adjustment........................................................................................................... 10A1-37
Inner Window Weatherstrip Replacement....................................................................................................10A1-37
Outer Window Weatherstrip Replacement..................................................................................................10A1-37
Rear Glass Run Channel Replacement....................................................................................................... 10A1-37
Window Regulator Replacement................................................................................................................. 10A1-38
Door Lock Replacement...............................................................................................................................10A1-39
Door Lock Control Assembly Replacement....................................... .......................................................... 10A1-41
Below Eyeline Outside Rear View Mirror Replacement.............................................................................. 10A1-41
G Model Intermediate Doors.............................................................................................................................10A1-42
DOORS 10A1-3
SUBJECT
PAGE
G Model Intermediate Doors (Continued)

Bumper Wedge Replacement.......................................................................................................................10A1-44
Window Replacement.................................................................................................................................. 10A1-45
Intermediate Front Door Lock Replacement............................................................................................... 1QA1-46
Intermediate Front Door Lock Control Replacement..................................................................................10A1-47
Intermediate Rear Door Lower Latch Replacement....................................................................................10A1-49
Intermediate Rear Door Upper Latch Replacement....................................................................................10A1-49
Intermediate Rear Door Control Assembly Replacement.......................................................................... 10A1-50
Intermediate Front Door Weatherstrip Replacement..................................................................................10A1-50
Intermediate Rear Door Weatherstrip Replacement....................................................................................10A1-51
G Model Sliding Side Door.............................................................................................................................. 10A1-53
Door Replacement........................................................................................................................................ 10A1-53
Hinge Assembly Replacement.....................................................................................................................10A1-53
Lower Roller Assembly Replacement.........................................................................................................10A1-54
Upper Front Roller Replacement.................................................................................................................10A1-54
Door Trim Panel Replacement....................................................................................................................10A1-58
Front Lock Replacement...............................................................................................................................10A1-59
Rear Lock Replacement...............................................................................................................................10A1-61
Lock Cylinder Replacement.........................................................................................................................10A1-61
Sliding Side Door Weatherstrip Replacement............................................................................................. 10A1-61
G Model Rear D oors........................................................................................................................................ 10A1-63
Door And Hinge Replacement.....................................................................................................................10A1-63
Door Adjustment....................................................................................................... ..................................10A1-64
Striker Replacement.................................................................................................................................... 10A1-64
Bumper Wedge Replacement.......................................................................................................................10A1-66
Swing Out W indow ...................................................................................................................................... 10A1-67
Left Door Lower Latch Replacement........................................................................................................... 10A1-67
Right Door Lower Latch Replacement......................................................................................................... 10A1-67
Right Door Upper Latch Replacement......................................................................................................... 10A1-69
Right Door Control Assembly Replacement............................................................................................... 10A1-69
Door Outside Handle Replacement............................................................................................................10A1-70
Check Strap Replacement.............................................................................................................................10A1-70
Check Assembly Replacement............................................................................................................... . .10A1-71
Left Door Weatherstrip Replacement........................................................................................................... 10A1-71
Right Door Weatherstrip Replacement....................................................................................................... 10A1-72
Special Tools....................................................................................................................................................10A1-74
10A1-4 DOORS
RV MODEL SIDE FRONT DOOR

Adjust
f t
T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in o r
o u t, a t t h e d o o r h in g e s .
1. A d ju s t th e d o o r to o b ta in a g a p o f 6 m m (0 .2 4 -in c h
0 .0 9 -in c h ) b e tw e e n th e r o c k e r p a n e l a n d th e d o o r.
1. Cowl
2. Door
3. Lower
H inge
4. B olt
5. Upper
H inge
6. B olt
7. B olt
2 . T h e g a p b e tw e e n th e d o o r a n d t h e r o o f p a n e l s h o u ld
b e 5 m m 2 m m (0 .1 9 -in c h 0 .0 9 -in c h ).
3 . A d ju s t th e d o o r to o b ta in a g a p o f 5 m m 2 m m
(0 .1 9 -in c h 0 .0 9 -in c h ) b e tw e e n th e d o o r s r e a r e d g e
a n d t h e r e a r d o o r p illa r .
4. T h e gap
b e tw e e n th e d o o r a n d th e w in d s h ie ld
s h o u ld b e 2 m m
1 .5 m m ( 0 . 0 8 - i n c h
5 . T h e d o o r s u r fa c e s h o u ld b e flu s h w ith th e o th e r p a n e ls
w ith in 1 .5 m m ( 0 .0 6 - in c h ) e x c e p t fo r t h e d o o r to
r o o f p a n e l s u r fa c e w h ic h s h o u ld b e flu s h w ith in
m m ( + 0 .0 6 -in c h ).
p illa r
0 .0 6 -in c h ).
F-00444
+ 1 .5
6 . T ig h t e n t h e h in g e b o lts .

Figure 1Door Hinge Components
NOTICE: Refer to N otice on page 10A1-1 of
this section.
DOOR AND HINGE

REPLACEMENT
1 . D o o r s t r ik e r b o lt.

O p e n th e d o o r.
E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
R e f e r to D o o r T rim P a n e l R e p la c e m e n t ,
a c c e s s to th e w ir in g h a rn e s s .
Adjust
f t
fo r
M a r k t h e p o s itio n o f t h e h in g e s o n t h e d o o r.
Tighten
2. D o o r h i n g e t o d o o r b o l t s ( 4 ) .
3. D o o r fr o m th e v e h ic le .
M a r k t h e p o s it io n o f t h e h in g e s o n t h e b o d y s i d e p illa r .
4 . H in g e to d o o r p illa r b o lts (6 ).
5 . D o o r p illa r to h in g e b o lt (7 ).
6. H i n g e s f r o m t h e v e h i c l e .
+ 4 -
B o lt to p r o p e r ly e n g a g e t h e d o o r lo c k .
2 . T ig h t e n t h e s tr ik e r b o lt.
S t r ik e r b o lt to 6 3 N m ( 4 6 ft. lb s .).
DOOR TRIM PANEL

REPLACEMENT
T o o is R e q u ir e d :
J -9 7 7 6 -0 1 D o o r H a n d le C lip R e m o v e r .

H in g e s to th e v e h ic le .
A lig n t h e h in g e s to t h e m a r k s o n t h e b o d y s id e p illa r s .
H in g e to d o o r p illa r b o lts (6 ).
D o o r p illa r to h in g e b o lt (7 ).
1 . W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 .
2. L o c k k n o b .
3. A rm
re s t to a r m re s t b ra c k e t s c re w s (7 7 ).
D o o r to th e v e h ic le .
4 . A rm
re s t fro m th e d o o r.
A lig n t h e m a r k s o n t h e d o o r to t h e h in g e s .
5 . S t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) .
D o o r h in g e to d o o r b o lts (4 ).
6. S t r a p a s s e m b l y s c r e w s ( 2 4 ) ( i f e q u i p p e d ) .
E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
R e fe r to
D o o r T rim
P a n e l R e p la c e m e n t,
J - 2 4 5 9 5 - B D o o r T rim P a d C lip R e m o v e r .
7. S t r a p a s s e m b ly (if e q u ip p e d ) .
fo r
8. D o o r t r i m p a n e l t o d o o r s c r e w s ( 2 2 ) .
9 . D o o r tr im p a n e l to d o o r r e t a in e r s u s in g J - 2 4 5 9 5 - B .
10. D o o r t r i m p a n e l f r o m t h e d o o r .
DOOR ADJUSTMENT
T o o ls R e q u ir e d :
J -2 2 5 8 5 -0 1
P r y th e to p o f th e p a n e l a w a y fr o m th e d o o r s id e
w in d o w s e a l c lip s .

D o o r H in g e B o lt W r e n c h .
J -2 3 4 5 7 -A W re n c h .
D o o r s tr ik e r b o lt u s in g J - 2 3 4 5 7 - A .
C h e c k t h a t a ll t h e t r im r e t a in e r s a r e s e c u r e ly f a s t e n e d ,
an d a re not
fa s te n e rs .
d am ag ed .
R e p la c e
any
d am ag ed
U s e to o l J - 2 2 5 8 5 - 0 1 w h e n lo o s e n in g t h e d o o r h in g e to
b o d y s id e p illa r b o lts . T h e r e a r f e n d e r b o lts m a y n e e d
D o o r t r im p a n e l o n to t h e d o o r s id e w in d o w s e a l c lip s .
to b e lo o s e n e d fo r a c c e s s to t h e s e b o lts .
D o o r tr im p a n e l to d o o r s c r e w s ( 2 2 ) .
D o o r t r im r e t a in e r s in to t h e d o o r p a n e l.
DOORS 10A1-5
A.
B.
C.
D.
2
5
5
6
mm
mm
mm
mm
1.5 mm (0.08-inch 0.06-inch)

2 mm (0.19-inch 0.09-inch)
2 mm (0.19-inch 0.09-inch)
2 mm (0.24-inch 0.09-inch)
W indshield P illar
Door A ssem bly
Roof Panel
Rocker Panel
Front D oor Rear P illar
F -0 0 4 4 5
Figure 2Door Adjustments

4 . S t r a p a s s e m b ly o n t o t h e d o o r (if e q u ip p e d ) .
5 . S t r a p a s s e m b ly s c r e w s (if e q u ip p e d ) .
7. A rm re s t to th e d o o r.
8 . A rm re s t to a rm re s t b ra c k e t s c re w s (7 7 ).
9. L o ck kn ob .
1 0 . W in d o w r e g u la to r h a n d le .
DOOR VENT/WINDOW RUN

CHANNEL ASSEMBLY
REPLACEMENT
T h e d o o r v e n t a n d th e fr o n t w in d o w ru n c h a n n e l a r e
o n e a s s e m b ly . T h i s a s s e m b ly is fit in to t h e f r o n t o f t h e
d o o r fra m e .
16. J-986-01
17. Spring C lip
18. Inside Handle
Push The Tool In

The D irection Of
The Arrow
F -0 1 2 2 7
Figure 3Door Striker

Figure 4Handle Clip Remover
10A1-6 DOORS
20
19.
20.
21.
22.
23.
24.
25.
77.
21
22
^25
R etainer
D oor Trim Panel
Arm Rest
Screw
Cover
Screw
Strap
Screw
F-00446
Figure 5Trim Panel Components

5 . D o o r v e n t/w in d o w
P l a c e t h e w i n d o w in t h e lo w e r e d p o s it io n .
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
R e p la c e m e n t.
2 . R u n c h a n n e l m o ld in g .
ru n
channel
a s s e m b ly
fro m
th e
v e h ic le .
P u ll t h e to p o f t h e v e n t b a c k w a r d s a w a y f r o m t h e
d o o r fra m e .
L if t a n d r o t a t e t h e a s s e m b l y o u t o f t h e d o o r .
-<- Install or Connect (Figure 6)
P u ll t h e m o ld in g o u t o f t h e v e n t a s s e m b ly o n ly .
3 . D o o r p a n e l to r u n c h a n n e l b o lt (3 1 ).
4 . D o o r to v e n tila to r s c r e w s ( 2 6 ) a n d s p a c e r s ( 2 7 ).
1. D o o r v e n t/w in d o w ru n c h a n n e l a s s e m b ly to th e v e h ic le .
R o ta te th e v e n t a s s e m b ly in to th e d o o r.
F it t h e a s s e m b ly in to t h e d o o r f r a m e .
2 . D o o r to v e n tila to r s c r e w s ( 2 6 ) a n d s p a c e r s (2 7 ) .
S t a r t w ith t h e s c r e w a t t h e to p o f t h e d o o r, a n d
w o rk d o w n w a rd .
3 . D o o r p a n e l to r u n c h a n n e l b o lts (3 1 ).
S e a t t h e c lip in to t h e v e n t , t h e n p u s h th e
r e m a in d e r o f t h e m o ld in g in to t h e r u n c h a n n e l.
5. D o o r tr im
p a n e l. R e f e r to D o o r T r im
P an el
VENT GLASS REPLACEMENT

CAUTION: Always wear heavy gloves when
handling glass to minimize the risk of injury.
REMOVAL (Figure 6)
1. O p e n t h e v e n t w in d o w .
2 . S q u ir t s o lv e n t o n t h e t a r - p a p e r - lik e fille r a ll a r o u n d t h e
g la s s c h a n n e l, o n b o th s id e s o f t h e g la s s .
3 . W h e n t h e fille r a n d s e a le r s o f t e n , p u ll t h e g la s s a n d t h e
o ld f ille r f r o m t h e c h a n n e l.
Screw
Spacer
D oor V ent/W indow G lass Run A ssem bly
Run C hannel M old ing
B olt
F-00447
Figure 6Door Vent/Window Run Channel

Components
INSTALLATION (Figure 6)
1. T h o r o u g h ly c le a n th e in s id e o f t h e g la s s c h a n n e l w ith
s a n d p a p e r to r e m o v e a ll r u s t a n d f o r e ig n m a tte r .
2 . C u t t h e n e w p ie c e o f g la s s c h a n n e l fille r
( 2 - in c h e s ) lo n g e r th a n r e q u ir e d .
3 . P o s itio n
th e
f ille r ( s o a p
s to n e d
s id e
aw ay
51
m m
fro m
th e
g la s s ) e v e n ly a r o u n d a n d o v e r t h e e d g e o f t h e g la s s
t h a t w ill b e in s e r t e d in t h e c h a n n e l . P r e s s t h e f ille r
fir m ly o n to th e e d g e o f t h e g la s s to e n s u r e a g o o d
DOORS 10A1-7
b o n d . ( U s u a ll y t h is is d o n e w it h a m e c h a n ic a l w in d o w
p r e s s .) S q u e e z e t o g e t h e r t h e d o u b le d e n d s o f t h e f ille r
w h ic h p r o je c t b e y o n d t h e e d g e o f t h e g la s s .
4 . B r u s h t h e in n e r c h a n n e l w ith s o a p s o lu tio n . D O
U S E G R E A S E O R O IL
5 . P r e s s th e g la s s a n d
fir m ly s e a te d .
32.
33.
34.
35.
36.
N O T
t h e f ille r in to t h e c h a n n e l u n til
G lass
W indow Sash
R egulator A ssem bly
R egulator Rail
N otch
F-00449
6 . T rim o ff e x c e s s fille r m a t e r ia l a r o u n d , a n d a t t h e e n d o f
th e c h a n n e l.
Figure 8Window Assembly Components
VENT WINDOW ADJUSTMENT
S l i d e t h e g l a s s f o r w a r d u n t i l t h e f r o n t r o l le r is in
lin e w it h t h e n o t c h in t h e s a s h c h a n n e l .
D is e n g a g e t h e r o lle r fr o m t h e c h a n n e l.
P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p u n t i l t h e
r e a r r o lle r is d is e n g a g e d .
P l a c e t h e i w n d o w in a l e v e l p o s i t i o n , a n d r a i s e it
s tr a ig h t u p a n d o u t o f t h e d o o r.
Adjust (Figure 7)
1 . R e m o v e t h e d o o r tr im p a n e l. R e f e r to D o o r T rim P a n e l
2 . B e n d th e ta b s o n th e a d ju s tm e n t n u t a w a y fr o m
th e
n u t.
3 . A d ju s t t h e v e n t b y p la c in g a w r e n c h o n t h e a d ju s tin g
n u t, a n d t h e n t u r n in g t h e v e n t w in d o w to t h e p r o p e r
te n s io n .
4 . B e n d th e ta b s o v e r th e a d ju s tm e n t n u t.
5 . In s t a ll t h e d o o r tr im
p a n e l. R e f e r to D o o r T rim
Panel
++
1. D o o r w in d o w g la s s .
DOOR WINDOW REPLACEMENT

L o w e r th e w in d o w in to th e d o o r fr a m e .
P u s h t h e w i n d o w f o r w a r d , t h e n t ilt it u p , a n d s l id e
t h e r e a r r o lle r in to t h e s a s h c h a n n e l.
S l i d e t h e g l a s s b a c k w a r d u n t i l t h e f r o n t r o l l e r is in
lin e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e
t h e r o lle r to t h e s a s h c h a n n e l.
S lid e th e
c h a n n e l.

L o w e r t h e g la s s to t h e b o tto m o f t h e d o o r.
1. D o o r tr im
p a n e l.
2.
R e fe r
D o o r v e n t/w in d o w r u n
D o o r V e n t/W in d o w
to
D o o r
T r im
c h a n n e l a s s e m b ly . R e fe r to
R u n C h a n n e l A s s e m b ly
M a s k o r c o v e r a n y s h a r p e d g e s th a t c o u ld s c r a tc h th e
g la s s .
3 . D o o r w in d o w g la s s .
re a rw a rd
in to
th e
g la s s
ru n
P an el
g la s s
R e m o v e a n y m a s k in g o r c o v e r in g .
2 . D o o r v e n t/w in d o w r u n
3. D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
10A1-8 DOORS
39. O uter Door Panel
F -0 0 4 5 1
Figure 10Outer Window Weatherstrip
REAR GLASS RUN

CHANNEL REPLACEMENT
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
L o w e r t h e w in d o w c o m p le te ly .
2 . In n e r a n d o u te r w in d o w w e a t h e r s tr ip s .
3 . D o o r to r u n c h a n n e l b o lts (4 1 ).
4 . R u n c h a n n e l fr o m t h e v e h ic le .
P u ll t h e r u n c h a n n e l u p w a r d s w h ile t w is t in g to
c le a r th e lo w e r b r a c k e t.
Figure 9Inner Window Weatherstrip
INNER WINDOW
WEATHERSTRIP REPLACEMENT
1. R u n c h a n n e l to t h e v e h ic le .
W o rk th e
r u n c h a n n e l in to t h e d o o r fr a m e . B e
c e r t a i n t h a t t h e g la s s is in t h e c h a n n e l .
2 . L o w e r d o o r to ru n c h a n n e l b o lt (4 1 ).
1. D o o r t r im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
P r y t h e c lip s o n t h e w e a t h e r s t r ip fr o m
p a n e l s h o u ld e r .
t h e tr im

1 . W e a t h e r s t r ip ( 3 7 ) to t h e t r im p a n e l.
P u s h t h e w e a t h e r s t r ip c lip s o n to t h e t r im
s h o u ld e r .
2. D o o r
tr im
p a n e l.
R e fe r
to
D oo r
T r im
panel
P an el
OUTER WINDOW
|<"| Remove or Disconnect (Figure 10)
L o w e r t h e w in d o w .
W e a th e rs tr ip (3 8 ) fro m th e d o o r.
P r y t h e w e a t h e r s t r ip c lip s fr o m t h e d o o r p a n e l.

W e a th e r s tr ip (3 8 ) to th e d o o r.
R a is e t h e w in d o w c o m p le te ly .
3 . U p p e r d o o r to r u n c h a n n e l b o lt (4 1 ).
2 . W e a t h e r s t r ip ( 3 7 ) f r o m t h e tr im p a n e l.
P u s h t h e w e a t h e r s t r ip c lip s o n to t h e d o o r p a n e l.
5 . D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
DOORS 10A1-9
33.
34.
35.
42.
W ind ow Sash
R egulator Rail
Bolt
28.
43.
44.
45.
46.
Bolt
Nut
Bolt
W iring Harness
F -0 0 4 5 4
F -0 0 4 5 3
F igure 13 P o w er W in do w R eg ula tor
Figure 12 M anual W in do w R eg ula tor
WINDOW REGULATOR
REPLACEMENT
M ANUAL REGULATOR
R a is e th e w in d o w
and
t a p e t h e g la s s
in t h e f u ll u p
p o s itio n u s in g c lo th b o d y t a p e .
1. D o o r tr im
p a n e l.
R e fe r
to
T r im
S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n , a n d
in s e r t t h e r e g u la to r d r iv e t h r o u g h t h e d o o r p a n e l.
P an el
R e m o v e t h e t a p e fr o m th e w in d o w .
P O W E R R E G U L A T O R
F o r th e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B
E L E C T R IC A L (S E C . 8 A ).
3 . W in d o w r e g u la to r .
S lid e th e r e g u la to r r e a r w a r d to d is e n g a g e t h e
r e a r r o lle r fr o m th e s a s h c h a n n e l. A ls o
d is e n g a g e t h e lo w e r r o lle r f r o m t h e r e g u la t o r r a il.
D is e n g a g e t h e f o r w a r d r o lle r fr o m th e
c h a n n e l a t th e n o tc h in th e s a s h c h a n n e l.
sash
C o l l a p s e t h e r e g u la t o r , a n d r e m o v e it t h r o u g h t h e
a c c e s s h o le in t h e d o o r .
R e m o v e o r D is c o n n e c t (F ig u re s 12 a n d 13)
R a i s e t h e w i n d o w a n d t a p e t h e g l a s s in t h e f u ll u p
2 . D o o r tr im
P an el
3 . R e m o v e c o n tr o l to d o o r tr im p a n e l b o lts .
|~n-| In s ta ll o r C o n n e c t (F ig u re 12)
T r im
P an el
2 . D o o r p a n e l to r e g u la to r b o lts ( 4 2 ) .
S lid e th e r e g u la to r r e a r w a r d to e n g a g e th e r e a r
r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e lo w e r
r o lle r t o t h e r e g u la t o r r a il.
2 . D o o r p a n e l to r e g u la t o r b o lts (4 2 ).
3. D o o r tr im
p a n e l. R e f e r to D o o r
D o o r
L u b r ic a t e t h e r e g u la t o r a n d t h e s a s h a n d r e g u la t o r r a ils
w ith lu b r ip la te o r e q u iv a le n t.
1. W in d o w r e g u la to r .
C o l l a p s e t h e r e g u la t o r , a n d i n s e r t it t h r o u g h t h e
U n f o ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d
r o lle r to t h e s a s h c h a n n e l a t t h e s a s h c h a n n e l
n o tc h .
4.
L a y th e c o n tr o l a s id e .
R e g u la t o r to d o o r p a n e l b o lts ( 4 5 ) a n d n u ts ( 4 4 ).
5 . W ir in g h a r n e s s f r o m t h e r e g u la to r .
S lid e
th e
r e g u la to r r e a r w a r d
to
d is e n g a g e
th e
r e a r r o lle r fr o m t h e s a s h c h a n n e l. A ls o
d is e n g a g e t h e lo w e r r o lle r fr o m t h e r e g u la t o r r a il.
D is e n g a g e t h e fo r w a r d r o lle r fr o m t h e
c h a n n e l a t t h e n o t c h in t h e s a s h c h a n n e l .
sash
C o l l a p s e t h e r e g u l a t o r , a n d r e m o v e it t h r o u g h t h e
a c c e s s h o l e in t h e d o o r .
10A1-10 DOORS
CAUTION: The n e xt ste p m u st be p erform ed
w he n th e re g u la to r is rem oved fro m th e d oo r.
The re g u la to r lift arm s are u n d e r te n sio n fro m
th e c o u n te rb a la n c e s p rin g and ca n c a u se
se rio u s in ju ry if th e m o to r is rem oved w ith o u t
lo c k in g th e s e c to r g ea r in p o sitio n .
D r ill a h o le t h r o u g h t h e r e g u la t o r s e c t o r g e a r a n d b a c k
p l a t e . D r i l l t h e h o l e a t l e a s t 1 2 . 7 m m ( 1/ 2- i n c h ) a w a y
fr o m t h e e d g e o f t h e s e c to r g e a r o r b a c k p la te . In s ta ll a
p a n h e a d s h e e t m e ta l ta p p in g s c r e w a t le a s t 1 9 m m
( 3/4 - in c h ) l o n g in t o t h e d r i ll e d h o l e t o l o c k t h e s e c t o r
g e a r in p la c e .
7. M o to r to r e g u la to r a t t a c h in g b o lts (2 8 ).
8 . M o t o r f r o m t h e r e g u la to r .
In s ta ll o r C o n n e c t (F ig u re s 12 a n d 13)
L u b ric a te th e
te e th .
m o to r d r iv e g e a r a n d
r e g u la to r s e c to r
R e g u la t o r m o t o r to r e g u la to r .
T h e m o to r p in io n g e a r te e th m u s t m e s h p r o p e r ly
w ith t h e s e c t o r g e a r t e e t h b e f o r e in s ta llin g t h e
m o to r to r e g u la to r s c r e w s .
47.
48.
49.
50.
51.
52.
R e g u la t o r m o to r to r e g u la to r b o lts (2 8 ) .
R e m o v e t h e s h e e t m e ta l s c r e w fr o m th e b a c k p la te a n d
s e c to r g e a r.
W in d o w r e g u la to r to t h e d o o r.
C o l l a p s e t h e r e g u l a t o r , a n d i n s e r t it t h r o u g h t h e
U n fo ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d
n o tc h .
S lid e th e r e g u la to r r e a r w a r d to e n g a g e th e r e a r
r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e r o lle r
to t h e r e g u la t o r r a il.
S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n .
W ir in g h a r n e s s to t h e r e g u la to r .
R e g u la t o r to d o o r p a n e l b o lts ( 4 5 ) a n d n u ts ( 4 4 ).
R e m o t e c o n tr o l to d o o r t r im p a n e l b o lts .
D o o r tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
B a tte r y g r o u n d c a b le .
Lock Knob
Inside Door Lock Rod
C lip
Lock A ssem bly
Inside Door Handle Rod
Screw
F -0 0 4 5 5
F igure 14 D oor L o c k C om p o n e n ts
+ 4 -
T ilt th e lo c k a s s e m b ly a w a y fr o m th e o u ts id e lo c k
c y lin d e r . P u ll t h e lo c k a s s e m b ly d o w n w a r d to
m a k e c le a r a n c e fo r th e in s id e lo c k ro d .
In s ta ll o r C o n n e c t (F ig u re 14)
L o c k a s s e m b ly to th e d o o r.
A lig n t h e in s id e lo c k r o d t o t h e h o le in t h e d o o r
p a n e l. T ilt t h e lo c k a s s e m b ly o n to t h e o u t s id e
lo c k c y lin d e r .
D o o r to lo c k a s s e m b ly s c r e w s (5 2 ).
In s id e d o o r lo c k k n o b .
O u ts id e d o o r
a s s e m b ly .
R e m o v e th e t a p e fr o m th e w in d o w .
DOOR LOCK REPLACEMENT
h a n d le
to
lo c k
ro d
o n to
th e
lo c k
C lip o n to t h e lo c k ro d .
P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d .
In s id e d o o r h a n d le to lo c k ro d o n to th e lo c k a s s e m b ly .
|<"| R e m o ve o r D is c o n n e c t (F ig u re 14)
C lip o n to t h e lo c k r o d .
1. D o o r t r im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2 . In s id e d o o r h a n d le to lo c k r o d c lip s (4 9 ) .
U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p
o f t h e c lip w h e r e it is c o n n e c t e d t o t h e r o d . P iv o t
t h e c lip a w a y fr o m t h e ro d .
3 . In s id e d o o r h a n d le to lo c k ro d fr o m th e lo c k .
4 . O u t s i d e d o o r h a n d l e t o lo c k r o d c lip .
POWER DOOR LOCK

MOTOR REPLACEMENT
R e fe r to C A B E L E C T R IC A L (S E C .
d ia g n o s is o f th e d o o r lo c k m o to r.
8 A ) fo r e le c tr ic a l
U s e t h e p r o c e d u r e g iv e n u n d e r s te p 2 .
5 . O u t s id e d o o r h a n d le to lo c k ro d fr o m t h e lo c k .
R e m o v e o r D is c o n n e c t (F ig u re 15)
6 . In s id e d o o r lo c k k n o b .
1 . B a tte r y g r o u n d c a b le .
7. D o o r to lo c k a s s e m b ly s c r e w s (5 2 ).
2 . D o o r tr im
p a n e l.
8 . L o c k a s s e m b ly fro m th e d o o r.
R e fe r
to
D o o r
T r im
P an el
DOORS 10A1-11
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
Bolt
O utside Handle Rod
Sm all Gasket
Handle A ssem bly
Key
Lock C ylinder
Gasket
Large Gasket
Retainer
C lip
F -0 0 4 5 7
Figure 16Outside Handle and Lock Cylinder

Components
48.
49.
50.
53.
78.
Inside D oor Lock Rod

C lip
Lock A ssem bly
M otor A ssem bly
Screw
5 . H a n d le w ith t h e c o n tr o l ro d fr o m t h e d o o r.
6 . G a s k e ts fro m th e d o o r.

1. L a r g e g a s k e t o v e r t h e l o c k r o d a n d o n t o t h e h a n d l e .
F -0 0 4 5 6
2 . H a n d le w ith th e lo c k ro d o n to th e d o o r.
3 . D o o r to o u ts id e h a n d le s c r e w (5 4 ) to th e p u s h b u tto n
Figure 15Power Door Lock Motor
s id e o f th e h a n d le .
E le c tr ic a l c o n n e c to r fr o m t h e m o to r.
D o o r to m o to r s c r e w s (7 8 ).
M o to r fr o m th e lo c k r o d .
S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o ff
5 . D o o r to o u ts id e h a n d le s c r e w (5 4 ) to th e o th e r s id e o f
th e h a n d le .
o f th e d o o r lo c k ro d .
4 . S m a ll g a s k e t b e tw e e n th e d o o r a n d th e h a n d le .
T ig h te n b o th s c r e w s .
6. M o t o r f r o m t h e d o o r .
6 . O u ts id e d o o r h a n d le to lo c k ro d to th e lo c k a s s e m b ly .
4-
7. C lip o n to t h e lo c k ro d .
1. M o t o r i n t o t h e d o o r .
2. M o t o r t o t h e lo c k r o d .
3.
4.
5.
6.
S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r
o n to th e d o o r lo c k ro d .
D o o r to m o to r s c r e w s (7 8 ).
E le c tr ic a l c o n n e c t o r to t h e m o to r.
D o o r t r im p a n e l. R e f e r to D o o r T rim P a n e l
B a tte r y g r o u n d c a b le .
DOOR OUTSIDE HANDLE

REPLACEMENT
P iv o t t h e c lip u p a n d o n to t h e lo c k r o d .
8. D o o r tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
DOOR LOCK CYLINDER

REPLACEMENT
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2 . L o c k c y lin d e r r e t a in in g c lip ( 6 2 ) fr o m t h e c y lin d e r .
S lid e t h e c lip o ff t h e c y lin d e r w ith a s c r e w d r iv e r .
3 . L o c k c y lin d e r a n d g a s k e t fr o m th e d o o r.
R
D
R
O
a is e t h e w in d o w c o m p le te ly .
o o r tr im
P an el
e p la c e m e n t.
u t s i d e d o o r h a n d l e t o lo c k r o d c lip .
o f t h e c l ip w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t
t h e c lip a w a y f r o m t h e r o d .
O u t s id e d o o r h a n d le to lo c k r o d fr o m t h e lo c k .
D o o r to o u ts id e h a n d le s c r e w s (5 4 ).

1. L o c k c y l i n d e r w i t h g a s k e t t o t h e d o o r .
T h e c y lin d e r ro d m u s t e n g a g e th e lo c k a s s e m b ly
le v e r .
2 . L o c k c y lin d e r ( 6 2 ) r e t a in in g c lip o n to t h e c y lin d e r .

3. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
10A1-12 DOORS
Figure 17Door Inside Handle
DOOR INSIDE HANDLE

REPLACEMENT
DOOR WEATHERSTRIP
REPLACEMENT
4-4 Remove or Disconnect (Figure 18)

1. D o o r t r im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
1 . S ill p la t e fr o m t h e v e h ic le .
2 . D o o r h a n d le s e a l.
2 . W e a t h e r s t r ip fr o m t h e p in c h w e ld f la n g e .
3 . H a n d le to d o o r s c r e w s (6 5 ).
4 . C o n tro l ro d fr o m th e in s id e h a n d le .
S l i d e t h e c l i p s o t h a t t h e l a r g e d i a m e t e r s l o t i s in
lin e w it h t h e lo c k r o d . T h e n , p u ll t h e r o d f r o m t h e
h a n d le .
5 . In s id e h a n d le fr o m th e d o o r.

1. C o n tro l ro d to th e in s id e h a n d le .
P la c e t h e r o d in to t h e c lip a n d t h e le v e r. S lid e t h e
c l ip s o t h a t t h e s m a l l d i a m e t e r s lo t is in l in e w i t h
th e lo c k ro d .
2.
H a n d le to d o o r s c r e w s (6 5 ).
4. D o o r
tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
P u ll t h e w e a t h e r s t r ip a w a y fr o m t h e f la n g e .
DOORS 10A1-13
68. Screw
69. M irror
70. Bolt
71. Bracket
72. G asket
F -0 0 4 6 0
Figure 19Outside Rear View Mirror Components
73. Below Eyeline

74. W est Coast

1 . W e a t h e r s t r ip to t h e p in c h w e ld f la n g e .
S ta r t a t th e b o tto m c e n te r o f th e d o o r o p e n in g .
T rim t h e w e a t h e r s t r ip , a n d b u tt t h e e n d s to g e th e r .
2 . S ill p la t e to t h e v e h ic le .
OUTSIDE REAR VIEW

MIRROR REPLACEMENT
F -0 0 4 6 1

1 . M ir r o r to b r a c k e t s c r e w .
Figure 20Below Eyeline and West Coast

Style Mirrors
2 . M ir r o r fr o m t h e d o o r.
3 . B r a c k e t to d o o r b o lts .
WEST COAST OUTSIDE

REAR VIEW MIRROR
REPLACEMENT
4 . B r a c k e t a n d g a s k e t fr o m t h e v e h ic le .

1 . B r a c k e t a n d g a s k e t to th e v e h ic le .
2 . B r a c k e t to d o o r b o lts .
1. M ir r o r
3 . M ir r o r to t h e b r a c k e t.
4 . M ir r o r to b r a c k e t s c r e w .

b ra c k e t
to
door
b ra c k e t
n u ts ,
b o lts ,
and
n u ts ,
b o lts ,
and
b u s h in g s .
2 . M ir r o r b r a c k e t fr o m t h e v e h ic le ,
3 . D o o r b r a c k e t n u ts a n d b o lts .
BELOW EYELINE OUTSIDE

REAR VIEW MIRROR
REPLACEMENT
B
4.
B ra c k e ts fro m th e d o o r.

1. D o o r b ra c k e ts to th e d o o r.
2 . D o o r b r a c k e t n u ts a n d b o lts .
1. M ir r o r c o v e r s c r e w .
3 . M ir r o r b r a c k e t to t h e d o o r b r a c k e ts .
4.
L if t t h e c o v e r , a n d p iv o t t h e m ir r o r t o w a r d s t h e w in d o w .
M ir r o r
b ra c k e t
to
door
b ra c k e t
b u s h in g s .
2 . M ir r o r to d o o r b o lts .
3 . M ir r o r a n d s e a l fr o m t h e d o o r.

1 . M ir r o r a n d s e a l to th e d o o r.
2 . M ir r o r to d o o r b o lts .
DOOR AIR VALVE

REPLACEMENT
P iv o t th e m ir r o r a w a y fr o m th e w in d o w , a n d lo w e r th e
1. D o o r tr im
p a n e l.
m ir r o r c o v e r.
2 . D o o r to a ir v a lv e s c r e w s .
3 . M ir r o r c o v e r s c r e w .
R e fe r
3 . A ir v a lv e f r o m t h e d o o r.
to
D oo r
T r im
P an el
10A1-14 DOORS
|++| Install or Connect (Figure 21)
1. A ir v a lv e to t h e d o o r.
3. D o o r
tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
Figure 21Door Air Valve
RV MODEL SIDE REAR DOORS
DOOR AND HINGE

REPLACEMENT
3 . H in g e to d o o r p illa r b o lts ( 8 0 ) .
M a r k th e p o s itio n o f th e h in g e s o n th e d o o r a n d o n th e
d o o r p illa r .
4 . D o o r fr o m t h e v e h ic le .
5 . H in g e to d o o r b o lts (8 0 ).
6 . H in g e s fr o m th e d o o r.
1. E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
2.
R e f e r to D o o r T rim P a n e l R e p la c e m e n t
a c c e s s to th e w ir in g h a r n e s s .
In n e r h in g e p illa r c o v e r s c r e w s (7 8 ) a n d c o v e r s (7 9 ).
fo r

1. H in g e s to th e d o o r.
A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k s .
DOORS 10A1-15
2.
1. A d ju s t th e d o o r to o b ta in a g a p o f 6 m m 2 m m
(0 .2 4 -in c h 0 .0 9 -in c h ) b e tw e e n th e r o c k e r p a n e l
a n d th e d o o r.
H in g e to d o o r b o lts (8 0 ).
3 . D o o r to t h e v e h ic le .
A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k s .
2 . T h e g a p b e tw e e n th e d o o r a n d th e ro o f p a n e l
s h o u ld b e 5 m m 2 m m (0 .1 9 -in c h 0 .0 9 -in c h ).
4 . H in g e to d o o r p illa r b o lts ( 8 0 ) .
5 . In n e r h in g e p illa r c o v e r s (7 9 ) a n d s c r e w s (7 8 ).
3 . A d ju s t th e d o o r to o b ta in a g a p o f 5 m m 2 m m
(0 .1 9 -in c h + 0 .0 9 -in c h ) b e tw e e n th e d o o r s r e a r
e d g e a n d t h e r e a r d o o r p illa r .
6 . E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
fo r
4 . T h e g a p b e tw e e n t h e d o o r a n d t h e c e n t e r p illa r
s h o u ld b e 5 m m
DOOR ADJUSTMENT
E
J -2 3 4 5 7 -A W re n c h .
D o o r s tr ik e r b o lt u s in g J - 2 3 4 5 7 - A .
Adjust (Figure 23)

T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in
o r o u t, a t t h e d o o r h in g e s .
2 m m (0 .1 9 -in c h 0 .0 9 -in c h ).
5 . T h e d o o r s u r f a c e s h o u ld b e flu s h w ith t h e o t h e r
p a n e ls w it h in 1 .5 m m ( 0 .0 6 - in c h ) e x c e p t fo r
t h e d o o r to r o o f p a n e l s u r fa c e w h ic h s h o u ld b e
f lu s h w it h in + 1 .5 m m ( + 0 .0 6 - in c h ) .
Install or Connect
NOTICE: Refer to N o tice on page 10A1-1 of

this section.
Door striker bolt.
10A1-16 DOORS
87. C ontrol A ssem bly
88. Retainer
89.
90.
91.
92.
93.
94.
95.
Bezel
Door Trim Panel
Screw
Arm Rest
Screw
Plate
Handle
F-00468
Figure 24Door Trim Panel Components

Adjust
B o lt to p r o p e r ly e n g a g e t h e d o o r lo c k .
Tighten
S t r ik e r b o lt to 6 3 N m ( 4 6 ft. lb s .).
DOOR TRIM PANEL

REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Door
Door
Door
S tra p
S
S
A
A
L
W
t r im
t r im
t r im
ass
p a n e l o n t o t h e d o o r s i d e w in d o w s e a l c lip s .
r e ta in e r s in to t h e d o o r p a n e l.
p a n e l to d o o r s c r e w s (9 3 ).
e m b ly o n to t h e d o o r (if e q u ip p e d ) .
tr a p a s s e m b ly s c r e w s (if e q u ip p e d ) .
t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) .
rm r e s t to th e d o o r.
r m r e s t to a r m r e s t b r a c k e t s c r e w s (9 1 ).
ock knob.
in d o w r e g u la to r h a n d le .

T o o ls R e q u i r e d :
J -9 8 8 6 -0 1
D o o r H a n d le C lip R e m o v e r .
1. W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 .
2. Lock knob.
3. A rm
re s t to a r m
re s t b ra c k e t s c re w s (9 1 ).
4 . A rm
re s t fro m th e d o o r.
STATIONARY GLASS/WINDOW
RUN CHANNEL ASSEMBLY
REPLACEMENT
T h e s t a t io n a r y g la s s a n d t h e r e a r w in d o w r u n c h a n n e l
a r e o n e a s s e m b ly . T h is a s s e m b ly fits in to t h e r e a r o f t h e
d o o r fra m e .
6 . S t r a p a s s e m b ly s c r e w s (if e q u ip p e d ) .
7 . S t r a p a s s e m b ly (if e q u ip p e d ) .
P l a c e t h e w in d o w in t h e lo w e r e d p o s it io n .
8 . D o o r t r im p a n e l to d o o r s c r e w s ( 9 3 ) .
D o o r tr im
p a n e l.
9 . D o o r t r im p a n e l to d o o r r e t a in e r s u s in g J - 2 4 5 9 5 - B .
10.
D o o r t r im p a n e l fr o m t h e d o o r.
P r y th e to p o f th e p a n e l a w a y fro m th e d o o r s id e
w in d o w s e a l c lip s .

C h e c k t h a t a ll t h e t r im r e t a in e r s a r e s e c u r e ly f a s t e n e d ,
a n d a r e n o t d a m a g e d . R e p la c e a n y d a m a g e d
fa s te n e rs .
R e fe r
to
D o o r
T r im
P an el
R u n c h a n n e l m o ld in g (9 6 ) .
P u ll t h e m o ld in g o u t o f t h e r u n c h a n n e l o n ly .
D o o r p a n e l to r u n c h a n n e l b o lt (9 9 ).
D o o r fr a m e to ru n c h a n n e l s c r e w (9 7 ).
S ta tio n a r y g la s s /w in d o w
th e d o o r.
ru n
c h a n n e l a s s e m b ly fro m
P u ll t h e t o p o f t h e c h a n n e l b a c k w a r d s a w a y fr o m
th e d o o r fra m e .
DOORS 10A1-17
L o w e r th e w in d o w to th e b o tto m o f th e d o o r.
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2 . S ta tio n a r y g la s s /w in d o w ru n c h a n n e l a s s e m b ly . R e fe r
to S ta t io n a r y G la s s /W in d o w
g la s s .
3 . D o o r w in d o w g la s s (1 0 0 ).
S l i d e t h e g l a s s r e a r w a r d u n t i l t h e r e a r r o l l e r is in
l in e w it h t h e n o t c h in t h e s a s h c h a n n e l .
P u s h t h e w i n d o w r e a r w a r d , t h e n t ilt it u p u n t il t h e
f r o n t r o lle r is d is e n g a g e d .
P l a c e t h e w i n d o w i n a l e v e l p o s i t i o n , a n d r a i s e it

1. D o o r w in d o w g la s s ( 1 0 0 ).
96.
97.
98.
99.
107.
108.
109.
Run Channel M o ld ing

Screw
S tationary G lass/W indow Run Channel
B olt
B olt
Front Glass Run Channel
N ut
F-00469
Figure 25Stationary Glass/Window Run Channel

Components
L ift a n d r o t a t e t h e a s s e m b l y o u t o f t h e d o o r .
L o w e r th e w in d o w in to th e d o o r fr a m e .
P u s h t h e w i n d o w r e a r w a r d , t h e n t ilt it u p , a n d
s lid e t h e fr o n t r o lle r in to t h e s a s h c h a n n e l.
S l i d e t h e g l a s s f o r w a r d u n t i l t h e r e a r r o l l e r is in
l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e
S lid e
th e
g la s s
fo rw a rd
in to
th e
g la s s
ru n
c h a n n e l.
R e m o v e a n y m a s k in g o r c o v e r in g .
2 . S ta tio n a r y g la s s /w in d o w r u n c h a n n e l a s s e m b ly . R e fe r
to S t a t io n a r y G la s s A /V in d o w R u n C h a n n e l A s s e m b ly
3. D o o r tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el

1 . S ta tio n a r y g la s s /w in d o w ru n c h a n n e l a s s e m b ly to th e
d o o r.
2.
R o t a t e t h e v e n t a s s e m b ly in to t h e d o o r.

1. D o o r
P u s h t h e m o ld in g in to t h e r u n c h a n n e l. T h e s lo t
a t t h e to p o f t h e m o ld in g m u s t b e o n to p o f t h e
m u s t p a s s th ro u g h th e ru n c h a n n e l
tr im
p a n e l.
D o o r
T r im
P an el
P r y t h e c lip s o n t h e w e a t h e r s t r ip fr o m
t h e tr im
1 . W e a t h e r s t r ip to t h e tr im p a n e l.
D o o r p a n e l to ru n c h a n n e l b o lt ( 9 9 ).
5. D o o r
to
m o ld in g s lo t.
4.
R e fe r
p a n e l s h o u ld e r .
3 . D o o r fr a m e to ru n c h a n n e l s c r e w (9 7 ).
T h e s c re w
p a n e l.
2 . W e a th e r s t r ip fr o m t h e tr im p a n e l.
ru n c h a n n e l.
tr im
R u n c h a n n e l m o ld in g .
INNER WINDOW
R e fe r
to
D op r
T r im
P an el
P u s h t h e w e a t h e r s t r ip c lip s o n to t h e t r im
s h o u ld e r .
2 . D o o r tr im
p a n e l.
R e fe r
to
D o o r T r im
panel
Panel
10A1-18 DOORS
100.
101.
102.
103.
104.
A.
Glass
F ille r
Sash Channel
R egulator
Bolt
N otch
Figure 26Window Assembly Components
OUTER WINDOW
L o w e r th e w in d o w .
1. W e a th e r s tr ip fro m th e d o o r.

1. W e a th e r s tr ip to t h e d o o r.
105. Inner W ind ow W eatherstrip

F -0 0 7 2 7
106. O uter W indow W eatherstrip
F -0 0 9 6 3
Figure 27Inner Window Weatherstrip

Figure 28Outer Window Weatherstrip
DOORS 10A1-19
FRONT GLASS RUN
CHANNEL REPLACEMENT
110.
111.
112.
113.
Bolt
W iring Harness
Nut
1. O u t e r w in d o w w e a t h e r s tr ip .
2 . D o o r to r u n c h a n n e l b o lt (1 0 7 ) a n d n u t (1 0 9 ).
P u ll t h e r u n c h a n n e l u p w a r d s w h ile tw is tin g to
c le a r t h e lo w e r b r a c k e t.

1. R u n c h a n n e l to th e v e h ic le .
2.
W o r k th e ru n c h a n n e l in to th e d o o r fr a m e . B e
D o o r to r u n c h a n n e l b o lt (1 0 7 ) a n d n u t (1 0 9 ).
3 . O u t e r w in d o w w e a t h e r s tr ip .
WINDOW REGULATOR
REPLACEMENT
MANUAL REGULATOR
110

1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
F -0 0 4 7 5
2.
D o o r w in d o w . R e f e r to D o o r W in d o w R e p la c e m e n t .
Figure 29Power Regulator
3 . D o o r p a n e l to r e g u la to r b o lts (1 0 4 ).
w ith lu b r ip la te o r e q u iv a le n t .
1. W in d o w r e g u la to r .
2.
D o o r p a n e l to r e g u la to r b o lts (1 0 4 ).
3 . D o o r w in d o w s . R e fe r to D o o r W in d o w R e p la c e m e n t .
4. D o o r
tr im
p a n e l.
R e fe r
CAUTION: The next step must be performed

when the regulator is removed from the door.
The regulator lift arms are under tension from
the counterbalance spring and can cause
serious injury if the motor is removed without
locking the sector gear in position.
to
D o o r
T r im
P an el
P O W E R R E G U L A T O R
F o r th e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B
L u b ric a te th e
1.
1. B a t te r y g r o u n d c a b le .
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
3 . D o o r w in d o w . R e fe r to D o o r W in d o w R e p la c e m e n t .
4.
R e g u la t o r to d o o r p a n e l b o lts (1 1 0 ) a n d n u ts (1 1 2 ).
5 . W ir in g h a r n e s s fr o m t h e r e g u la to r .
1.
m o to r d riv e
gear and
te e th .
R e g u la t o r m o t o r to r e g u la to r .
[<"[ Remove or Disconnect (Figure 29)

D o o r
( 1/ 2- i n c h ) a w a y
k p la te . In s ta ll a
a t le a t 1 9 m m
lo c k t h e s e c to r
8 . M o t o r f r o m t h e r e g u la to r .
2.
p la t e . D r ill t h e h o le a t le a s t 1 2 .7 m m
fro m th e e d g e o f th e s e c to r g e a r o r b a c
p a n h e a d s h e e t m e ta l ta p p in g s c re w
( 3/ 4 - in c h ) l o n g i n t o t h e d r i l l e d h o l e t o
g e a r in p la c e .
7. M o to r to r e g u la to r a tta c h in g s c r e w s .
T h e m o t o r p in io n g e a r t e e t h m u s t m e s h p r o p e r ly
w ith t h e s e c to r g e a r t e e th b e fo r e in s ta llin g t h e
m o to r to r e g u la to r s c r e w s .
R e g u la t o r m o to r to r e g u la to r s c r e w s .
R e m o v e th e s h e e t m e ta l s c r e w fr o m th e b a c k p la te a n d
s e c to r g e a r.
3 . W in d o w r e g u la to r to th e d o o r.
C o l l a p s e t h e r e g u la t o r , a n d i n s e r t it t h r o u g h t h e
4 . W ir in g h a r n e s s to t h e r e g u la to r .
5 . R e g u la t o r to d o o r p a n e l b o lts (1 1 0 ) a n d n u ts (1 1 2 ).
6 . D o o r w in d o w . R e fe r to D o o r W in d o w R e p la c e m e n t .
10A1-20 DOORS
117. Remote C ontrol To Lock Rod

118. Inside Door Handle To Lock Rod
119. Power Door Lock M otor
F -0 0 4 7 6
Figure 30Door Lock Components

7. D o o r tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
4. O u ts id e d o o r
a s s e m b ly .
D o o r
T r im
P an el
3 . In s id e d o o r h a n d le to lo c k r o d fr o m t h e lo c k .
4 . O u t s i d e d o o r h a n d l e to lo c k r o d c lip .
8 . L o c k a s s e m b ly fro m th e d o o r.
T ilt t h e lo c k a s s e m b ly a w a y fr o m t h e o u ts id e lo c k
c y lin d e r . P u ll t h e lo c k a s s e m b ly d o w n w a r d to
m a k e c le a r a n c e fo r t h e in s id e lo c k ro d .
8. D o o r tr im
p a n e l.
R e fe r
to
D o o r
d ia g n o s is o f th e d o o r lo c k m o to r.
R e fe r
to
th e
o u ts id e
P an el
D o o r
lo c k
T rim
P an el
3 . E le c tr ic a l c o n n e c to r fr o m t h e m o to r.
4 . D o o r to m o to r s c r e w s .
5 . M o to r fr o m t h e lo c k ro d .
o f t h e d o o r lo c k ro d .
6 . M o to r fro m th e d o o r.
1. L o c k a s s e m b ly to th e d o o r.
o n to
T rim
POWER DOOR LOCK

MOTOR REPLACEMENT

a s s e m b ly
lo c k
2 . D o o r tr im
p a n e l.
7. D o o r to lo c k a s s e m b ly s c r e w s (1 1 6 ).
T ilt t h e lo c k
c y lin d e r .
th e
6 . R e m o v e c o n tr o l to lo c k a s s e m b ly c lip a n d r o d .
o n to
U s e t h e p r o c e d u r e g iv e n u n d e r s te p 2 .
ro d
In s id e d o o r h a n d le to lo c k r o d c lip (1 1 5 ).
o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t
lo c k
6 . In s id e d o o r h a n d le to lo c k r o d o n to t h e lo c k a s s e m b ly .
2.
to
5 . C lip o n to t h e lo c k ro d .
1. D o o r t r im
p a n e l. R e f e r to
h a n d le
2 . D o o r to lo c k a s s e m b ly s c r e w s (1 1 6 ).
1. M o to r in to th e d o o r.
3 . R e m o t e c o n t r o l t o lo c k a s s e m b l y r o d a n d c lip .
2 . M o to r to t h e lo c k r o d .
DOORS 10A1-21
Screw
Sm all Gasket
Key
F -0 0 4 7 7
5 . D o o r to o u ts id e h a n d le s c r e w (1 2 0 ) to th e o th e r s id e o f
th e h a n d le .
Figure 31Door Outside Handle Components
S lid e th e r u b b e r m o u n t a t t h e to p o f th e m o to r
o n to th e d o o r lo c k r o d .
. D o o r to m o to r s c re w s .
. E le c tr ic a l c o n n e c to r to t h e m o to r.
. D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
p a n e l.
to
D o o r
T r im
P an el

1. D o o r t r im
p a n e l.

R
D
R
2. O
R e fe r
DOOR INSIDE HANDLE

REPLACEMENT
DOOR OUTSIDE
HANDLE REPLACEMENT
R e fe r
to
D o o r
T r im
P an el
T r im
P an el
3 . H a n d le a s s e m b ly to d o o r s c r e w s (1 3 1 ).
4 . C o n tro l ro d fr o m th e in s id e h a n d le .
s h o n th e to p
t h e r o d . P iv o t
S l id e t h e c l ip s o t h a t t h e l a r g e d i a m e t e r s lo t is in
lin e w ith t h e lo c k r o d . T h e n , p u ll t h e r o d fr o m t h e
h a n d le .
lo c k .
D o o r to o u ts id e h a n d le s c r e w s (1 2 0 ).
tr im
. B a tte r y g r o u n d c a b le .
a is e t h e w in d o w c o m p le te ly .
o o r tr im
p a n e l. R e f e r to D o o r
e p la c e m e n t.
u t s i d e d o o r h a n d l e to lo c k r o d c lip .
U s in g a fla t b la d e d s c r e w d r iv e r , p u
o f t h e c l ip w h e r e it is c o n n e c t e d t o
O u ts id e d o o r h a n d le to lo c k ro d fr o m th e
P iv o t t h e c lip u p a n d o n to t h e lo c k r o d .
8. D o o r
H a n d le w ith th e c o n tr o l ro d fr o m t h e d o o r.
G a s k e ts fro m th e d o o r.
1. L a r g e g a s k e t o v e r t h e l o c k r o d a n d o n t o t h e h a n d l e .
2. H a n d l e w it h t h e lo c k r o d o n t o t h e d o o r .
3 . D o o r to o u ts id e h a n d le s c r e w (1 2 0 ) to th e p u s h b u tto n
4. S m a l l g a s k e t b e t w e e n t h e d o o r a n d t h e h a n d l e .
5 . In s id e h a n d le fr o m th e d o o r.

1. C o n tro l ro d to th e in s id e h a n d le .
P l a c e t h e r o d in to t h e c lip a n d t h e le v e r . S lid e t h e
c lip s o t h a t t h e s m a l l d ia m e t e r s lo t is in lin e w it h
th e lo c k ro d .
2 . H a n d le a s s e m b ly to d o o r s c r e w s (1 3 1 ).
4 . D o o r tr im p a n e l.
R e fe r
to
D oor
T rim
Panel
10A1-22 DOORS
Figure 32Door Inside Handle Components
REMOTE CONTROL
REPLACEMENT
1. D o o r t r im
p a n e l.
2.
R e fe r
to
D o o r
134. W eatherstrip
T r im
134
P an el
R e m o te c o n tr o l to lo c k a s s e m b ly ro d .
o f t h e c l ip w h e r e it is c o n n e c t e d t o t h e r o d . P iv o t
P u ll t h e r o d f r o m t h e r e m o t e c o n tr o l.
3 . D o o r p a n e l to r e m o t e c o n tr o l b o lts (1 2 9 ).
4 . R e m o te
h o le .
c o n tr o l le v e r s a n d
ro d s th ro u g h
th e
access
th e
access
[-<-[ Install or Connect (Figure 32)

1. R e m o te
h o le .
c o n tr o l le v e r s a n d
ro d s th ro u g h
2 . D o o r p a n e l to r e m o t e c o n tr o l b o lts (1 2 9 ).
3 . R e m o te c o n tr o l to lo c k a s s e m b ly ro d .
P iv o t t h e c lip u p a n d o n to t h e lo c k ro d .
4 . D o o r tr im
p a n e l.
R e fe r
to
D oo r
T rim
P an el
DOOR WEATHERSTRIP
REPLACEMENT
F-00965

1 . S ill p la t e f r o m t h e v e h ic le .
2 . W e a t h e r s t r ip fr o m t h e p in c h w e ld f la n g e .
Figure 33Door Weatherstrip
DOORS 10A1-23
1. W e a t h e r s t r ip to t h e p in c h w e ld f la n g e .
S ta r t a t th e b o tto m c e n te r o f th e d o o r o p e n in g .
T r im t h e w e a t h e r s t r ip , a n d b u tt t h e e n d s to g e th e r .
2 . S ill p la t e to t h e v e h ic le .
DOOR AIR VALVE

REPLACEMENT
-+l Remove or Disconnect (Figure 34)
1. D o o r tr im
p an el
R e fe r
to
D oo r
T r im
P an el
T r im
P an el
3 . A ir v a lv e fr o m t h e d o o r.

1. A ir v a lv e to t h e d o o r.
Figure 34Door Air Valve
3. D o o r
tr im
p a n e l.
R e fe r
to
D oor
RV MODEL REAR DOORS

DOOR ADJUSTMENT
DOOR AND HINGE

REPLACEMENT
E a c h o f t h e t w o d o o r s m u s t f ir s t b e a d ju s t e d in t h e d o o r
o p e n in g b e fo r e a d ju s tin g t h e d o o r to d o o r c le a r a n c e .
|"| Remove or Disconnect (Figure 35)
M a r k t h e p o s itio n o f t h e d o o r a n d t h e d o o r o p e n in g o n
t h e h in g e s .
T h e d o o r h e i g h t s o t h a t t h e r e is a g a p o f 5 m m 2 . 3
m m (0 .1 9 0 -in c h 0 .0 9 -in c h ) b e tw e e n th e ro o f p a n e l
1 . S t r a p p in .
a n d th e r e a r d o o r p a n e l.
R e fe r to
D o o r T rim
Panel
R e p la c e m e n t
fo r
3 . R e a r d o o r h in g e a c c e s s p lu g s c r e w , a n d t h e a c c e s s
p lu g (if e q u ip p e d ) .
2 . T h e g a p b e tw e e n th e b o tto m o f th e d o o r p a n e l (n o t th e
b o tto m o f t h e o u t e r p a n e l) a n d t h e p la tfo r m p a n e l
s h o u ld b e 7 m m (0 .2 8 0 -in c h ). T h is m e a s u r e m e n t
s h o u ld
b e ta k e n
on
each
d o o r in d iv id u a lly fr o m
6 . D o o r o p e n in g to h in g e b o lts (1 3 7 ).
3 . T h e r e a r d o o r o u te r p a n e l to th e b o d y s id e o u te r p a n e l
g a p to 5 m m 2 .3 m m (0 .1 9 0 -in c h 0 .0 9 -in c h ).
7. H in g e s fr o m th e d o o r o p e n in g .
4 . T h e d o o r to d o o r c le a r a n c e b e t w e e n t h e le ft a n d r ig h t
o u te r d o o r p a n e ls s h o u ld b e 5 m m
2 .3 m m
(0 .1 9 0 -in c h 0 .0 9 -in c h ).

1. H in g e s to th e d o o r o p e n in g .
A lig n t h e h in g e w ith t h e p r e v io u s ly m a d e m a r k .
STRIKER REPLACEMENT
2 . D o o r o p e n in g to t h e h in g e b o lts (1 3 7 ).
- Remove or Disconnect (Figure 37)

A lig n t h e h in g e w ith t h e p r e v io u s ly m a d e m a r k .
1. S tr ik e r to d o o r f r a m e b o lts (1 5 0 ).
2 . S tr ik e r fr o m th e d o o r fr a m e .
4 . D o o r to h in g e b o lts (1 3 9 ).
3 . S p a c e r (if e q u ip p e d ) .
5 . R e a r d o o r h in g e a c c e s s p lu g a n d s c r e w (if e q u ip p e d ) .
R e fe r to
D o o r T rim
w ir in g h a rn e s s .
7 . S t r a p p in .
th e
s i d e o f t h e d o o r . T h e d o o r s h o u ld b e in its n o r m a l
c l o s e d p o s i t i o n . ( T h e o u t e r r e a r d o o r p a n e l is 1 4 m m
1 .5 m m ( 0 . 5 6 0 - i n c h 0 .0 6 - in c h ) a w a y f r o m t h e r e a r
p la tfo r m p a n e l w h e n n o r m a lly c lo s e d ).
4 . D o o r to h in g e b o lts (1 3 9 ).
Adjust (Figure 36)
P a n e i
fo r a c c e s s to th e
-* Install or Connect (Figure 37)

1. S p a c e r (a s r e q u ir e d ).
2 . S tr ik e r to t h e d o o r fr a m e .
3 . S tr ik e r to d o o r f r a m e b o lts (1 5 0 ).
10A1-24 DOORS
137.
138.
139.
140.
141.
Bolt
Hinge
Bolt
Screw
Cover
F -0 0 4 6 4
Figure 35Hinge Components
14 mm 1.5 mm (0.560-inch 0.06-inch)
F -0 0 9 6 2
DOORS 10A1-25
152
147.
148.
149.
150.
151.
152.
Spacer
B um per
Screw
Bolt
S triker
Spacer
150. Bolt
151. S triker
152. Spacer
F -0 0 4 7 1
F -0 0 4 7 0
Figure 38Striker Adjustment
Figure 37Striker Components

Adjust (Figure 38)
DOOR TRIM PANEL

REPLACEMENT
T h e s tr ik e r to d o o r la tc h c le a r a n c e s o th a t t h e r e a r e 4 .4
m m (0 .1 7 2 -in c h ) b e t w e e n t h e s tr ik e r a n d t h e d o o r la tc h
w hen
t h e d o o r is in t h e s e c o n d a r y l a t c h e d
p o s itio n .
( T h e d o o r is l a t c h e d b u t n o t f u ll y c l o s e d . ) A n 11/e 4 - in c h
1. L o w e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 8 ).
d ia m e t e r d r ill b it m a y b e u s e d to g a g e th is c l e a r a n c e .
2 . L o w e r g a r n is h m o ld in g .
3 . C h e c k s tra p fro m th e d o o r.
4 . D o o r tr im p a n e l to d o o r s c r e w s (1 5 6 ).
BUMPER WEDGE REPLACEMENT
IE! Remove or Disconnect (Figure 37)
1. B u m p e r to u p p e r d o o r fr a m e s c r e w s (1 4 9 ).
2 . B u m p e r a n d s p a c e r.
6 . U p p e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 3 ).
7. U p p e r g a r n is h m o ld in g .
+ -
1. U p p e r g a r n is h m o ld in g .
2 . U p p e r g a r n is h m o ld in g to d o o r s c r e w s ( 1 5 3 ).
n- Install or Connect (Figure 37)
4 . D o o r tr im p a n e l to d o o r s c r e w s (1 5 6 ).
5 . C h e c k s tr a p to t h e d o o r.
6 . L o w e r g a r n is h m o ld in g .
7. L o w e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 8 ).
2 . B u m p e r.
3 . B u m p e r to u p p e r d o o r fr a m e s c r e w s (1 4 9 ).
Adjust
T h e b u m p e r to d o o r c l e a r a n c e s o t h a t t h e r e is 1 m m
(0 .0 4 -in c h ) b e tw e e n th e b u m p e r a n d th e d o o r w h e n th e
d o o r is in t h e s e c o n d a r y p o s i t i o n . ( T h e d o o r is l a t c h e d
b u t n o t fu lly c lo s e d ).
WINDOW REPLACEMENT
If a g l a s s is c r a c k e d b u t s t ill i n t a c t , it s h o u l d b e
c r is s c r o s s e d w it h m a s k in g t a p e to r e d u c e t h e r is k o f in ju r y
a n d / o r d a m a g e to t h e v e h ic le . If a c r a c k e x t e n d s t o t h e
e d g e o f t h e g la s s , m a r k t h e d o o r w ith a p ie c e o f c h a lk a t
th e p o in t w h e r e th e c r a c k m e e ts th e w e a t h e r s tr ip . L a te r,
w h e n e x a m in in g th e fla n g e o f th e o p e n in g fo r a c a u s e o f
th e c r a c k , s ta r t a t th e p o in t m a r k e d .
10A1-26 DOORS
Screw
G arnish M old ing
D oor Trim Panel
Screw
Lower G arnish
M olding
158. Screw
153.
154.
155.
156.
157.
153
---
155
'
\\
\Jr ssr~\
158'
157
F -0 2 7 4 0

It is i m p o r t a n t t h a t t h e c a u s e o f t h e c r a c k b e
d e t e r m in e d a n d t h e c o n d itio n c o r r e c te d , b e fo r e t h e n e w
g la s s
is
in s ta lle d . T h e
cau se
o f th e
c ra c k
m ay
be
an
o b s tr u c tio n o r h ig h s p o t s o m e w h e r e a r o u n d t h e f la n g e o f
t h e o p e n in g ; c r a c k in g m a y n o t o c c u r u n til p r e s s u r e fr o m
t h e h ig h s p o t o r o b s t r u c t io n b e c o m e s p a r t ic u la r ly h ig h
d u e to w in d s , e x t r e m e s o f t e m p e r a tu r e , o r r o u g h te r r a in .
RIGHT DOOR LOWER

LATCH REPLACEMENT
1. D o o r t r im
p a n e l.

th e
3 . W in d o w fr o m t h e w e a t h e r s tr ip .
4.
th e c o n tro l
L o w e r la tc h to d o o r s c r e w s (1 6 5 ).
5 . L o w e r la tc h w ith th e ro d fr o m th e d o o r.
1. L o w e r la tc h w ith t h e ro d to t h e d o o r.
2 . L o w e r la tc h to d o o r s c r e w s (1 6 5 ).
2 . A s i x m m ( 1/ 4 - i n c h ) c o r d i n t h e w e a t h e r s t r i p g r o o v e . T h e
3 . L o w e r la tc h to c o n tr o l a s s e m b ly
a s s e m b ly .
3 . W in d o w
P an el
1. W e a t h e r s t r ip to t h e g la s s .
about 5
T r im
|++| Install or Connect
++ Install or Connect (Figure 40)
e n d s s h o u ld o v e r la p
w in d o w b o tto m .
D o o r
t h e c lip a w a y fr o m t h e r o d .
H a v e a n a s s is ta n t o u ts id e th e c a b b y th e w in d o w .
F o r c e th e w e a t h e r s tr ip fr o m th e fla n g e fr o m
in s id e w ith a p u t t y k n ife .
to
3 . L o w e r la tc h to c o n tr o l a s s e m b ly ro d fr o m
a s s e m b ly .
2 . W e a th e r s tr ip a n d g la s s fr o m t h e f la n g e .
R e fe r
2 . D o o r lo c k a c c e s s c o v e r.
1. W e a t h e r s t r ip s e a l b y r u n n in g a p u tty k n ife b e t w e e n t h e
f la n g e a n d th e w e a t h e r s tr ip (in s id e a n d o u ts id e th e
d o o r).
H a v e a n a s s is t a n t p u ll t h e c o r d fr o m in s id e t h e
c a b to s e a t t h e lip o f t h e w e a t h e r s t r ip o n t h e
fla n g e .
cm
(6 -in c h e s )
a n d w e a t h e r s tr ip o n th e fla n g e fr o m
th e c a b .
Brush soapy water on the flange.
a t th e
o u ts id e
ro d
in to t h e c o n tr o l
P iv o t t h e c lip o n to t h e r o d .
5 . D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
DOORS 10A1-27
RIGHT DOOR UPPER

LATCH REPLACEMENT
1. D o o r t r im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
2 . D o o r lo c k a c c e s s c o v e r .
3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d fr o m
a s s e m b ly .
th e c o n tro l
Figure 42Right Door Upper Latch
10A1-28 DOORS
1. C o n tr o l a s s e m b ly th r o u g h th e a c c e s s h o le .
2.
D o o r to c o n tr o l a s s e m b ly b o lts (1 7 3 ).
3 . E le c t r ic a l d o o r a c t u a t o r (if e q u ip p e d ) .
4. U p p e r
and
lo w e r
door
la tc h
ro d s
to
th e
c o n tro l
T r im
P an el
a s s e m b ly .
P iv o t t h e c lip s o n to t h e r o d s .
6. D o o r tr im
p a n e l.
R e fe r
to
D o o r
DOOR OUTSIDE HANDLE

REPLACEMENT
I+-+I Remove or Disconnect (Figure 44)
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
3 . O u t s i d e d o o r h a n d l e to lo c k r o d c lip .
U s in g a fla t b la d e d s c r e w d r iv e r , p u s h o n t h e to p
o f t h e c lip w h e r e it is c o n n e c t e d to t h e r o d . P iv o t
5 . D o o r to o u ts id e h a n d le s c r e w s (1 7 4 ).
6 . H a n d le w ith th e c o n tr o l ro d fr o m th e d o o r.
7. G a s k e ts fro m th e d o o r.
Figure 43Right Door Control Assembly
Install or Connect
4.
1. L a r g e g a s k e t o v e r th e lo c k ro d a n d o n to th e h a n d le .
2.
U p p e r la tc h to d o o r b o lts (1 6 8 ).
5 . U p p e r la tc h w ith t h e ro d fr o m t h e d o o r.
Install or Connect
1. U p p e r la tc h w ith t h e ro d to t h e d o o r.
2 . U p p e r la tc h to d o o r b o lts (1 6 8 ).
3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d in to th e c o n tr o l
a s s e m b ly .
P iv o t t h e c lip o n to t h e ro d .
4 . D o o r lo c k a c c e s s c o v e r .
5. D o o r tr im
P an el
p a n e l.
th e h a n d le .
9. D o o r tr im
p a n e l.

tr im
RIGHT DOOR CONTROL

ASSEMBLY REPLACEMENT
1. D o o r
H a n d le w ith t h e lo c k ro d o n to t h e d o o r.
R e fe r
to
D oo r
T r im
P an el
3 . U p p e r a n d lo w e r d o o r
R e fe r
to
D o o r
LEFT DOOR LOWER

LATCH REPLACEMENT
la tc h
ro d s
fro m
th e
c o n tro l
a s s e m b ly .
T rim
1. L a tc h to d o o r s c r e w s (1 8 2 ).
2 . L a tc h fro m th e d o o r.
4 . E le c tr ic d o o r a c t u a t o r (if e q u ip p e d ) .
5 . D o o r to c o n tr o l a s s e m b ly b o lts (1 7 3 ).
1. L a tc h to th e d o o r.
6 . C o n tr o l a s s e m b ly t h r o u g h t h e a c c e s s h o le .
2 . L a tc h to d o o r s c r e w s (1 8 2 ).
P an el
DOORS 10A1-29
174.
175.
176.
177.
178.
179.
180.
181.
Screw
Sm all Gasket
O utside Handle
Large Gasket
Key
Door Lock C ylinder
Seal
Retainer
F -0 0 8 2 9
Figure 44Door Outside Handle Components

CHECK STRAP REPLACEMENT

++
1. B ra c k e t.
2 . B r a c k e t to in n e r p a n e l b o lts (1 8 7 ).
1. P in .
3 . S tr a p to th e d o o r.
2 . S t r a p to d o o r b o lts (1 8 4 ).
3. S tra p .
4 . S tr a p to d o o r b o lts (1 8 4 ).
5 . P in .
4 . B r a c k e t to in n e r p a n e l b o lts (1 8 7 ).
RIGHT DOOR WEATHERSTRIP

REPLACEMENT
5 . B ra c k e t.

1. W e a th e rs tr ip fro m
(o r e q u iv a le n t).
t h e d o o r u s in g 3 M
R e le a s e A g e n t
jQ [ Clean
182
T h e d o o r a n d w e a t h e r s t r ip o f a ll t h e o ld c e m e n t .

1. W e a th e r s tr ip to th e d o o r
A d h e s iv e (o r e q u iv a le n t).
162.
163.
164.
182.
183.
Screw
B um per
Spacer
Screw
Latch A ssem bly
u s in g
3M
W e a th e rs tr ip
LEFT DOOR WEATHERSTRIP

REPLACEMENT
Figure 45Left Door Lower Latch
1. W e a t h e r s t r ip to d o o r f a s t e n e r s u s in g J - 2 4 5 9 5 - B .
10A1-30 DOORS
184.
185.
186.
187.
188.
F -0 0 4 7 9
Figure 46Check Strap Components

2 . W e a t h e r s t r ip fr o m t h e d o o r u s in g 3 M R e le a s e a g e n t (o r
e q u iv a le n t).
ijji
Clean

1. W e a t h e r s t r ip to t h e d o o r u s in g
2 . W e a th e r s tr ip to d o o r fa s te n e r s .
3M
W e a th e r s tr ip
SECONDARY WEATHERSTRIP
REPLACEMENT
1. W e a th e r s tr ip fro m
Clean
- 4 -
1. W e a th e r s tr ip to th e d o o r
Figure 47Right Door Weatherstrip
u s in g
3M
W e a th e r s tr ip
DOORS 10A1-31
189. W eatherstrip
190. P lastic Nails
191. Fastener
191
F -0 0 4 8 1
Figure 48Left Door Weatherstrip
Figure 49Door Secondary Weatherstrip
10A1-32 DOORS
G MODEL SIDE FRONT DOORS

191.
192.
193.
194.
195.
U pper H inge
B olt
Screw
Cover
Lower
H inge
193
F -0 0 4 8 3
DOOR AND HINGE

REPLACEMENT
++
1. E le c t r ic a l w ir in g h a r n e s s fr o m t h e d o o r (if e q u ip p e d ) .
R e f e r to D o o r T r im P a d R e p l a c e m e n t
fo r
2 . K ic k p a n e l (if e q u ip p e d ) .
3 . H in g e b o lt c o v e r s c r e w (1 9 3 ).
4 . H in g e b o lt c o v e r.
M a r k t h e p o s itio n o f t h e h in g e s o n t h e d o o r a n d d o o r
p illa r .
S u p p o rt th e d o o r.
5 . D o o r f r a m e to h in g e b o lts (1 9 2 ).
6 . D o o r fr o m th e v e h ic le .
7. H in g e to d o o r b o lts .
8 . H in g e s fr o m th e d o o r.
DOOR ADJUSTMENT
1. H in g e s to th e d o o r.
J -2 3 4 5 7 -A # 5 0 T o rx W re n c h .
2 . H in g e to d o o r b o lts .
A lig n t h e h in g e s to t h e p r e v io u s ly m a d e m a r k .
1. L o c k s t r i k e r p r o t e c t o r s c r e w ( 1 9 6 ) .
2. L o c k s t r i k e r p r o t e c t e r .
A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k .
4 . D o o r f r a m e to h in g e b o lts (1 9 2 ).
5 . H in g e b o lt c o v e r .
7. H in g e b o lt c o v e r s c r e w (1 9 3 ) .
8 . H in g e b o lt c o v e r.
P la c e th e t a b o n t h e c o v e r in to th e s lo t.
6 . H in g e b o lt c o v e r s c r e w s (1 9 3 ).
R e fe r to
Door
T r im
Panel
R e p la c e m e n t
L o o s e n t h e d o o r h in g e b o lts a s n e e d e d to a d ju s t t h e
d o o r.
Adjust (Figure 52)
8 . E le c t r ic a l w ir in g h a r n e s s to t h e d o o r (if e q u ip p e d ) .
3. S p rin g .
4 . D o o r s tr ik e r u s in g J - 2 3 4 5 7 - A .
5. S p a c e r.
fo r
T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d a n d in o r
DOORS 10A1-33

1. A d ju s t th e d o o r to o b ta in a g a p o f 4 .5 m m 0 .5 m m
(0 .1 8 -in c h 0 .0 2 -in c h ) b e tw e e n th e fr o n t d o o r a n d th e
ro o f p a n e l.
2 . T h e g a p b e tw e e n th e ro c k e r p a n e l a n d th e fro n t d o o r a t
its b a s e s h o u ld b e 6 m m 0 .5 m m ( 0 .2 5 - in c h
0 .0 2 -in c h ).
3 . A d ju s t t h e d o o r to o b ta in a g a p o f 4 .5 m m 0 .5 m m
(0 .1 8 -in c h 0 .0 2 -in c h ) b e tw e e n th e d o o rs r e a r e d g e
a n d t h e r e a r d o o r p illa r .
4 . T h e g a p b e tw e e n th e d o o rs fro n t e d g e a n d th e re a r
e d g e o f th e fe n d e r s h o u ld b e 4 .5 m m
0 .5 m m
(0 .1 8 -in c h 0 .0 2 -in c h ).
T ig h te n t h e d o o r h in g e b o lts th a t w e r e lo o s e n e d .

1 . H in g e b o lt c o v e r .
P la c e t h e t a b o n t h e c o v e r in to t h e s lo t.
2 . H in g e b o lt c o v e r s c r e w (1 9 3 ).

this section.
5 . D o o r s tr ik e r .
6 . S p rin g .
7. L o c k s tr ik e r p r o te c te r .
8 . L o c k s tr ik e r p r o t e c t e r s c r e w ( 1 9 6 ) .
DOOR TRIM PANEL

REPLACEMENT
J - 9 8 8 6 -0 1 D o o r H a n d le C lip R e m o v e r .
1. W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 .
2 . W in d o w r e g u la to r h a n d le b e z e l.
3 . D o o r lo c k c o n t r o l a s s e m b ly h a n d le u s in g J - 9 8 8 6 - 0 1 .
4 . C o n tr o l a s s e m b ly h a n d le b e z e l.
5 . A s s is t h a n d le (if e q u ip p e d ) .
6 . A r m r e s t (if e q u ip p e d ) ( f ig u r e 5 5 ) .
4 . S p a c e r to t h e d o o r s tr ik e r .
7 . D o o r tr im o u t e r p a n e l s c r e w s (if e q u ip p e d ) .
10A1-34 DOORS
Inner Panel
Seal
Screw
Bezel
Door Handle
W indow H andle
F-00486
Figure 53Door Trim Inner Panel

++
8 . D o o r t r im o u t e r p a n e l (if e q u ip p e d ) .
P u ll t h e p a n e l a w a y fr o m t h e r e ta in e r s .
9 . D o o r tr im in n e r p a n e l s c r e w s .
P l a c e t h e w in d o w in t h e lo w e r e d p o s it io n .
1. D o o r t r im
p a n e l.
1 0 . D o o r tr im in n e r p a n e l.
Install or Connect (Figures 5 3 and 5 4 )
R e fe r
to
D o o r
1 . D o o r t r im in n e r p a n e l.
P u ll t h e m o ld in g o u t o f t h e v e n t a s s e m b l y o n ly .
3 . D o o r p a n e l to r u n c h a n n e l b o lt ( 2 2 8 ) .
3 . D o o r tr im o u t e r p a n e l (if e q u ip p e d ) .
4 . D o o r to v e n tila to r s c r e w s ( 2 2 3 ) .
P u s h t h e p a n e l in to t h e r e ta in e r .
4 . D o o r t r im o u t e r p a n e l s c r e w s (if e q u ip p e d ) .
5. A rm
P an el
2 . D o o r t r im in n e r p a n e l s c r e w s .
T r im
5 . D o o r v e n t/w in d o w
v e h ic le .
r e s t (if e q u ip p e d ) ( f ig u r e 5 5 ) .
c h a n n e l a s s e m b ly
fro m
th e
P u ll t h e to p o f t h e v e n t b a c k w a r d s a w a y fr o m t h e
d o o r fra m e .
L ift a n d r o t a t e t h e a s s e m b ly o u t o f t h e d o o r .
6 . A s s is t h a n d le (if e q u ip p e d ) .
7. C o n tr o l a s s e m b ly h a n d le b e z e l.
ru n
8 . W in d o w r e g u la to r h a n d le b e z e l.
9 . T h e c lip s to t h e w in d o w r e g u la t o r h a n d le a n d t h e d o o r
lo c k c o n tr o l a s s e m b ly h a n d le .
1. D o o r v e n t /w in d o w r u n c h a n n e l a s s e m b ly to t h e v e h ic le .
1 0 . W in d o w r e g u la to r h a n d le .
P u s h th e h a n d le o n to th e s h a ft.
1 1 . D o o r lo c k c o n tr o l a s s e m b ly h a n d le .
R o t a t e t h e v e n t a s s e m b ly in to t h e d o o r.
2 . D o o r to v e n tila to r s c r e w s ( 2 2 3 ) .
P u s h th e h a n d le o n to th e s h a ft.
DOOR VENT/WINDOW RUN

CHANNEL ASSEMBLY
REPLACEMENT
T he door vent and
th e fr o n t w in d o w
ru n
S t a r t w ith t h e s c r e w a t t h e to p o f t h e d o o r, a n d
w o rk d o w n w a rd .
3 . D o o r p a n e l to r u n c h a n n e l b o lt ( 2 2 8 ) .
4.
R u n c h a n n e l m o ld in g .
c h a n n e l a re
P u s h th e
c h a n n e l.
o n e a s s e m b ly . T h is a s s e m b l y is f it in to t h e f r o n t o f t h e
D o o r
d o o r fra m e .
tr im
c o rn e r o f th e
p a n e l.
m o ld in g
in to
th e
ru n
R efer to D oor Trim Panel
DOORS 10A1-35
218. A ssist Strap

219. Screw
220. Bezel
F-00487
Figure 54Door Trim Outer Panel
VENT GLASS REPLACEMENT

REMOVAL (Figure 57)
1. O p e n th e v e n t w in d o w .
2 . S q u ir t s o lv e n t o n t h e t a r - p a p e r - lik e f ille r a ll a r o u n d t h e
g la s s c h a n n e l, o n b o th s id e s o f t h e g la s s .
3 . W h e n t h e fille r a n d s e a le r s o fte n , p u ll t h e g la s s a n d th e
o ld f ille r f r o m t h e c h a n n e l.
INSTALLATION
1 . T h o r o u g h ly c le a n t h e in s id e o f t h e g la s s c h a n n e l w ith
s a n d p a p e r to r e m o v e a ll r u s t a n d f o r e ig n m a tte r .
2 . C u t th e n e w p ie c e o f g la s s c h a n n e l fille r 5 1
( 2 - in c h e s ) lo n g e r th a n r e q u ir e d .
m m
3 . P o s itio n
th e
th e
fille r (s o a p
s to n e d
s id e
aw ay
fro m
g la s s ) e v e n ly a r o u n d a n d o v e r t h e e d g e o f t h e g la s s
t h a t w ill b e in s e r t e d in t h e c h a n n e l . P r e s s t h e f ille r
10A1-36 DOORS
26.
27.
29.
30.
31.
223.
224.
225.
226.
227.
228.
229.
Figure 57Door/Vent Window Run Channel

Components
Screw
Run Channel M olding
Bolt
Rear Run Channel A ssem bly
Bolt
Bolt
Door Vent/Run Channel A ssem bly
In s ta ll t h e d o o r t r im
p a n e l. R e f e r to D o o r T rim P a n e l

F -0 0 4 9 1
Figure 56Door Run Channel Assemblies

f ir m ly o n to t h e e d g e o f t h e g la s s to e n s u r e a g o o d
b o n d . ( U s u a ll y t h is is d o n e w it h a m e c h a n ic a l w in d o w
p r e s s .) S q u e e z e t o g e t h e r t h e d o u b le d e n d s o f t h e f ille r
w h ic h p r o je c t b e y o n d t h e e d g e o f t h e g la s s .
4 . B r u s h t h e in n e r c h a n n e l w ith s o a p s o lu tio n . D O N O T
U S E G R E A S E O R O IL .
5 . P r e s s t h e g la s s a n d
fir m ly s e a te d .
Screw
Spacer
D oor Vent/W indow G lass Run A ssem bly
Run Channel M olding
B olt
F-00447

L o w e r t h e g la s s to t h e b o tto m o f t h e d o o r.
t h e fille r in to t h e c h a n n e l u n til
6 . T rim o ff e x c e s s f ille r m a t e r ia l a r o u n d , a n d a t t h e e n d o f
th e c h a n n e l.
VENT WINDOW ADJUSTMENT

Adjust (Figure 58)
R e m o v e t h e d o o r t r im p a n e l. R e f e r to D o o r T rim P a n e l
B e n d th e ta b s o n th e a d ju s tm e n t n u t a w a y fr o m th e
n u t.
A d ju s t t h e v e n t b y p la c in g a w r e n c h o n t h e a d ju s tin g
n u t, a n d th e n t u r n in g t h e v e n t w in d o w to t h e p r o p e r
te n s io n .
B e n d th e ta b s o v e r th e a d ju s tm e n t n u t.
F-00448
Figure 58Vent Window Adjustment
DOORS 10A1-37
230.
231.
232.
233.
234.
235.
236.
237.
238.
239.
WINDOW STOP ASSEMBLY

ADJUSTMENT
G lass
Sash A ssem bly
O uter W indow W eatherstrip
Inner W indow W eatherstrip
R egulator Rail
B olt
W asher
B olt
R egulator
Stop
1. R e m o v e t h e d o o r t r im p a n e l. R e f e r to D o o r T rim P a n e l
2.
L o w e r t h e w i n d o w u n t i l it is f l u s h w i t h t h e w i n d o w s i ll .
3 . L o o s e n t h e g la s s s to p b o lt, a n d a d ju s t t h e s to p u n til
t h e g la s s is c o m p le t e l y f lu s h w it h t h e w i n d o w s ill ( f i g u r e
5 9 ).
4 . T ig h t e n t h e b o lt.
5 . In s ta ll th e tr im
pad.
R e fe r
to
D oor
T rim
Panel
INNER WINDOW
L o w e r t h e w in d o w .
1. W e a th e rs tr ip fro m th e d o o r.
+ 4 -
1. W e a th e r s tr ip to th e d o o r.
F -0 0 4 9 2
Figure 59Door Window Components

1. D o o r
tr im
p a n e l.
R e fe r
2 . D o o r v e n t/w in d o w ru n
to
D o o r
T r im
P an el
L o w e r th e w in d o w .
1. W e a th e rs tr ip fro m th e d o o r.
g la s s .
3 . D o o r w in d o w g la s s (2 3 0 ) .
S l id e t h e g la s s f o r w a r d u n t il t h e f r o n t r o lle r is in
l in e w it h t h e n o t c h in t h e s a s h c h a n n e l .
P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p u n t i l t h e
r e a r r o lle r is d is e n g a g e d .
P l a c e t h e w i n d o w i n a l e v e l p o s i t i o n , a n d r a i s e it

1. D o o r w in d o w g la s s (2 3 0 ) .
R
2. D
R
3. D
R
OUTER WINDOW
L o w e r t h e w in d o w in to t h e d o o r f r a m e .
P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p , a n d s l i d e
t h e r e a r r o lle r in to t h e s a s h c h a n n e l.
S l i d e t h e g l a s s b a c k w a r d u n t i l t h e f r o n t r o l l e r is in
l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e
S lid e t h e g la s s r e a r w a r d in to t h e g la s s r u n
c h a n n e l.
e m o v e a n y m a s k in g o r c o v e r in g .
o o r v e n t/w in d o w ru n c h a n n e l a s s e m b ly . R e fe r to
e p la c e m e n t.
o o r tr im
P an el
e p la c e m e n t.
+ 4-
1. W e a th e rs tr ip to th e d o o r.
REAR GLASS RUN

CHANNEL REPLACEMENT
1. D o o r t r im
3 . D o o r to r u n c h a n n e l b o lts ( 2 2 5 a n d 2 2 7 ) .
P an el
P u ll t h e r u n c h a n n e l u p w a r d s w h ile t w is t in g to
c le a r th e lo w e r b r a c k e t.
1.
R u n c h a n n e l to t h e v e h ic le .
W o r k t h e r u n c h a n n e l in to t h e d o o r f r a m e
Be
L o w e r d o o r to r u n c h a n n e l b o lt ( 2 2 7 ) .
U p p e r d o o r to r u n c h a n n e l b o lt (2 2 5 ) .
In n e r a n d o u t e r w in d o w w e a t h e r s tr ip s .
D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
10A1-38 DOORS
WINDOW REGULATOR
REPLACEMENT
MANUAL REGULATOR
R a is e th e w in d o w a n d t a p e th e g la s s
1. D o o r
tr im
p a n e l.
R e fe r
to
in t h e f u ll u p
D oo r
T r im
P an el
2 . D o o r p a n e l to r e g u la t o r b o lts (2 3 7 ) .
3 . W in d o w r e g u la to r ( 2 3 8 ) .
S lid e t h e r e g u la to r r e a r w a r d to d is e n g a g e t h e
r e a r r o lle r fr o m th e s a s h c h a n n e l. A ls o
sash
Install or Connect
w ith lu b r ip la te o r e q u iv a le n t .
1. W in d o w r e g u la to r (2 3 8 ).
U n f o ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d
n o tc h .
S lid e t h e r e g u la to r r e a r w a r d to e n g a g e t h e r e a r
r o lle r t o t h e r e g u la t o r r a il.
S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n , a n d
231.
240.
241.
242.
243.
244.
245.
246.
in s e r t t h e r e g u la to r d r iv e th r o u g h t h e d o o r p a n e l.
Sash Channel
Bum per
Stop
Bolt
W asher
Bolt
Nut
Power R egulator
2 . D o o r p a n e l to r e g u la to r b o lts (2 3 7 ) .
3. D o o r tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
F -0 0 4 9 3
R e m o v e th e t a p e fr o m t h e w in d o w .
Figure 60Power Window Regulator
POWER REGULATOR
F o r t h e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B
R a is e t h e w i n d o w a n d t a p e t h e g la s s in t h e f u ll u p
2 . D o o r tr im
p a n e l.
CAUTION: The next step must be performed

when the regulator is removed from the door.
The regulator lift arms are under tension from
the counterbalance spring and can cause
serious injury if the motor is removed without
locking the sector gear in position.
R e fe r
to
D oo r
T r im
P an el
3 . R e m o t e c o n tr o l to d o o r tr im p a n e l b o lts .
L a y th e c o n tr o l a s id e .
4 . R e g u la t o r to d o o r p a n e l b o lts ( 2 4 4 ) a n d n u ts (2 4 5 ) .
5 . W ir in g h a r n e s s f r o m t h e r e g u la to r .
7 . M o to r to r e g u la to r a t t a c h in g s c r e w s .
6 . W in d o w r e g u la to r ( 2 4 6 ) .
S lid e th e r e g u la to r r e a r w a r d to d is e n g a g e th e
r e a r r o lle r fr o m t h e s a s h c h a n n e l. A ls o
C o l la p s e t h e r e g u la t o r , a n d r e m o v e it t h r o u g h t h e
p l a t e . D r i l l t h e h o l e a t l e a s t 1 2 . 7 m m ( 1/ 2- i n c h ) a w a y
fr o m t h e e d g e o f t h e s e c to r g e a r o r b a c k p la te . In s ta ll a
p a n h e a d s h e e t m e ta l ta p p in g s c r e w a t le a s t 1 9 m m
( 3/ 4 - in c h ) l o n g i n t o t h e d r i ll e d h o l e t o l o c k t h e s e c t o r
g e a r in p l a c e .
sash
8 . M o t o r fr o m t h e r e g u la to r .
t l Install or Connect (Figure 60)

E3
L u b ric a te th e
te e th .
m o to r d riv e g e a r a n d
1. Regulator motor to regulator.
DOORS 10A1-39
247
Lock A ssem bly

C lip
Inside Handle Rod
Inside Lock Rod
C lip
Power Lock Rod
249
268. B olt
ZDD
F -0 0 4 9 4
F -0 0 4 9 5
Figure 61Door Lock With Lock Rods
2.
Figure 62Door Lock Attachments
T h e m o to r p in io n g e a r t e e t h m u s t m e s h p r o p e r ly
w ith t h e s e c t o r g e a r t e e t h b e f o r e in s ta llin g t h e
m o to r to r e g u la r s c r e w s .
R e g u la to r m o to r to r e g u la to r s c r e w s .
3 . R e m o v e c o n tr o l a s s e m b ly . R e fe r to R e m o te C o n tr o l
4.
R e m o v e t h e s h e e t m e t a l s c r e w fr o m t h e b a c k p la te a n d
s e c to r g e a r.
Run
6 . L o c k fro m th e d o o r.
R e a r G la s s
5 . D o o r to lo c k s c r e w s ( 2 6 7 ) .
3 . W in d o w r e g u la to r to t h e d o o r.
R e a r g la s s r u n c h a n n e l. R e f e r to
C h a n n e l R e p la c e m e n t.
U n fo ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d
n o tc h .
S lid e t h e r e g u la to r r e a r w a r d to e n g a g e t h e r e a r
r o lle r to t h e r e g u la t o r r a il.
5 . R e g u la t o r to d o o r p a n e l b o lts ( 2 4 4 ) a n d n u ts (2 4 5 ).
6 . R e m o t e c o n tr o l to d o o r tr im p a n e l b o lts .
R e fe r
to
D oo r
T r im
- +
L o w e r t h e lo c k in t h e d o o r f a r e n o u g h t o p r o v id e
c le a r a n c e fo r th e in s id e lo c k ro d .
1. L o c k to th e d o o r.
S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n .
4 . W ir in g h a r n e s s to t h e r e g u la to r .
7. D o o r t r im
p a n e l.
A lig n t h e lo c k r o d w it h t h e h o le in t h e t o p o f t h e
d o o r p a n e l.
P an el
2 . D o o r to lo c k s c r e w s (2 6 7 ) .
8 . B a t t e r y g r o u n d c a b le .
3 . R e a r g la s s r u n c h a n n e l. R e f e r to R e a r G la s s
C h a n n e l R e p la c e m e n t.
R e m o v e th e ta p e fr o m th e w in d o w .

1. D o o r t r im
p a n e l.
2 . D o o r lo c k k n o b .
R e fe r
Run
4 . R e m o te c o n tr o l a s s e m b ly . R e f e r to R e m o t e C o n tr o l
A s s e m b ly .
5 . D o o r lo c k k n o b .
to
D o o r
T r im
P an el
6. D o o r tr im
p a n e l.
R e fe r
to
D o o r
T rim
P an el
10A1-40 DOORS
POWER DOOR LOCK
MOTOR REPLACEMENT
Refer to CAB ELECTRICAL (SEC. 8A) for electrical
diagnosis of the door lock motor.
1. B
2. D
R
3. E
4. D
a tte r y g r o u n d c a b le .
o o r tr im
p a n e l. R e fe r
to
D oo r
T r im
P an el
e p la c e m e n t.
le c tr ic a l c o n n e c t o r fr o m t h e m o to r.
o o r to m o to r s c r e w s (2 6 8 ).
5 . M o to r fr o m th e lo c k ro d .
S lid e t h e r u b b e r m o u n t a t t h e to p o f t h e m o to r o ff
6. M o to r fro m th e d o o r.
- -
1. M o to r in to t h e d o o r.
2 . M o to r to th e lo c k ro d .
3 . D o o r to m o to r s c r e w s (2 6 8 ).
4 . E le c tr ic a l c o n n e c t o r to th e m o to r.
p a n e l. R e fe r to D o o r
5. D o o r tr im
T r im
P an el
DOOR OUTSIDE
HANDLE REPLACEMENT
253.
254.
255.
256.
Bolt
Small Gasket
Door Handle
Large Gasket
257.
258.
259.
260.
Retainer
Key
Lock C ylinder
Gasket
F-00496
Figure 63Outside Handle and Lock Cylinder

Components

D oo r
R
2. D
3. H
4. G
tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
e p la c e m e n t.
o o r to o u ts id e h a n d le s c r e w s (2 5 3 ).
a n d le fro m th e d o o r.
a s k e ts fro m th e d o o r.

1. L a rg e g a s k e t o n to th e h a n d le .
th e h a n d le .
T ig h t e n b o th s c r e w s .
5 . D o o r tr im
p a n e l. R e fe r
to
D oo r
T r im
P an el
DOOR LOCK CYLINDER

REPLACEMENT
248.
261.
262.
263.
Inside Handle Rod

C ontrol A ssem bly
Screw
C lip
248
261
1. D o o r
tr im
p a n e l.
R e fe r
to
D oo r
T r im
P an el
2 . L o c k c y lin d e r r e t a in in g c lip fr o m t h e c y lin d e r .
3 . L o c k c y lin d e r a n d g a s k e t fr o m t h e d o o r.
F-00497
Figure 64Door Lock Control
DOORS 10A1-41
El
1. C o n tr o l to th e v e h ic le .
2 . C o n tr o l a s s e m b ly to th e lo c k a s s e m b ly ro d .
T w is t t h e c o n t r o l a s s e m b l y (w it h
c lip ) o n to t h e
ro d .
P iv o t t h e c lip o n t o t h e r o d .
3 . D o o r p a n e l to c o n tr o l a s s e m b ly s c r e w s (2 6 2 ).
4 . D o o r tr im
P an el
DOOR WEATHERSTRIP
REPLACEMENT
1 . W e a t h e r s t r ip f r o m t h e d o o r u s in g 3 M
2 . P la s tic n a ils fr o m t h e d o o r.
JQB Clean
T h e d o o r o f a ll t h e o ld c e m e n t .

1. W e a t h e r s t r ip a d h e s iv e to t h e d o o r . U s e 3 M
W e a th e r s tr ip A d h e s iv e (o r e q u iv a le n t).
2 . W e a th e r s tr ip to th e d o o r.
L o c a t e t h e w e a t h e r s t r i p p a r t n u m b e r , a n d p l a c e it
a t t h e to p o f t h e v e n t w in d o w .
P r e s s t h e p la s t ic n a ils in to t h e d o o r.
264. Weatherstrip
265. Plastic Nail
BELOW EYELINE OUTSIDE

REAR VIEW MIRROR
REPLACEMENT
I Remove or Disconnect (Figure 20)
F-00498
Figure 65Door Weatherstrip
1. L o c k c y lin d e r w ith g a s k e t to t h e d o o r.
T h e c y lin d e r ro d m u s t e n g a g e t h e lo c k a s s e m b ly
le v e r .
2 . L o c k c y lin d e r r e t a in in g c lip o n t o t h e c y lin d e r .

3. D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
DOOR LOCK CONTROL

|< >| Remove or Disconnect (Figure 64)
1. D o o r t r im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2 . D o o r p a n e l to c o n tr o l a s s e m b ly s c r e w s (2 6 2 ).
3 . C o n tr o l a s s e m b ly fr o m th e lo c k a s s e m b ly ro d .
P iv o t t h e c lip a w a y f r o m
th e ro d a t th e c o n tro l
a s s e m b ly .
T w is t t h e c o n t r o l a s s e m b l y o f f t h e r o d .
4 . C o n tr o l fr o m t h e v e h ic le .
L ift t h e c o v e r , a n d p iv o t t h e m ir r o r t o w a r d s t h e w in d o w .
2 . M ir r o r to d o o r b o lts a n d n u t.
3 . M ir r o r a n d s e a l fr o m t h e d o o r.
1. M ir r o r c o v e r s c r e w .
1. M ir r o
2 . M ir r o
P iv o t
m ir r o
3 . M ir r o
r a n d s e a l to th e d o o r.
r to d o o r b o lts a n d n u t.
th e m ir r o r a w a y fr o m th e w in d o w , a n d lo w e r th e
r c o v e r.
r c o v e r s c re w .
10A1-42 DOORS
G MODEL INTERMEDIATE DOORS
DOOR AND HINGE

REPLACEMENT
7. H in g e s fr o m th e d o o r.
8 . R e ta in e r s (2 7 4 ), s e a ls (2 7 3 ), a n d g r o m m e ts (2 7 2 ) fr o m
t h e d o o r o r t h e h in g e s .
1. E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
R e f e r to D o o r T r im P a n e l R e p l a c e m e n t

1. G r o m m e t to th e d o o r.
fo r
M a rk
w ax p
2 . H in g e
3. S tra p
t h e p o s itio n o f t h e d o o r o n t h e h in g e s u s in g a
e n c il.
h o le p lu g s o n t h e b o d y s i d e p illa r .
p in ( 2 7 5 ) f r o m t h e b r a c k e t .
R e m o v e t h e s n a p r in g f r o m t h e p in , a n d p u ll t h e
p in .
4 . H in g e to t h e b o d y p illa r b o lts ( 2 7 0 ).
6 . H in g e to d o o r b o lts ( 2 7 0 ).
2 . H in g e to th e d o o r.
3 . H in g e to d o o r b o lts (2 7 0 ).
A lig n t h e h in g e to t h e p r e v io u s ly m a d e m a r k .
4 . T h e s e a ls a n d r e ta in e r s to t h e b o d y h a lf o f t h e h in g e .
6 . H in g e to b o d y p illa r b o lts (2 7 0 ) .
7 . S t r a p p in ( 2 7 5 ) to t h e b r a c k e t .
8. S n a p r i n g t o t h e p i n .
9 . H in g e h o l e p lu g s o n t h e b o d y s i d e p illa r .
10.
E le c tr ic a l w ir in g h a r n e s s (if e q u ip p e d ) .
a c c e s s to t h e w ir in g h a r n e s s .
fo r
DOOR ADJUSTMENT
277
J -2 3 4 5 7 -A W re n c h .
1 . D o o r lo c k s t r ik e r f r o m t h e r e a r in t e r m e d ia t e d o o r u s in g
J -2 3 4 5 7 -A .
275.
276.
277.
278.
279.
280.
Pin
Bracket
Bolt
Ring
Strap
Pin
2 . U p p e r a n d lo w e r r e a r i n t e r m e d ia t e d o o r s tr ik e r s .
Loosen
d o o rs .
th e
h in g e
b o lts
as
n e c e s s a ry
to
a d ju s t th e
Adjust
279
278
F -0 0 5 0 0
Figure 67Check Strap Components
E a c h o f t h e t w o d o o r s m u s t f ir s t b e a d ju s t e d in t h e d o o r
o p e n in g b e fo r e a d ju s tin g t h e d o o r to d o o r c le a r a n c e .
T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in o r
DOORS 10A1-43
4 mm 0.5 mm (0.16-inch 0.020-inch)
282
F -0 0 5 0 1

T h e d o o r h e ig h t s o t h a t t h e r e is a g a p o f 4 . 5 m m 0 .5
m m (0 .1 8 -in c h 0 .0 2 0 -in c h ) b e tw e e n th e d o o r s a n d
th e ro o f p a n e l.
2. T h e g a p b e t w e e n t h e d o o r a n d t h e r o c k e r p a n e l t o 6
m m
0 .5 m m (0 .2 4 -in c h
0 .0 2 0 -in c h ).
287
T h e g a p b e t w e e n t h e d o o r s a n d t h e b o d y a t t h e h in g e
p illa r s to 4 m m 0 .5 m m ( 0 .1 6 -in c h 0 .0 2 0 - in c h ) .
T h e g a p b e tw e e n th e fr o n t a n d r e a r in te r m e d ia te d o o rs
to 6 m m 0 .5 m m (0 .2 5 -in c h 0 .0 2 0 -in c h ).
T ig h t e n t h e h in g e b o lts th a t w e r e lo o s e n e d .
Install or Connect
1.
287. S triker
288. Latch
A. 4.4 mm (0.172-inch)
287
U p p e r a n d lo w e r r e a r in t e r m e d ia t e d o o r s t r ik e r s to t h e
body.
D o o r lo c k s tr ik e r to t h e r e a r in t e r m e d ia t e d o o r u s in g
J -2 3 4 5 7 -A .
F -0 0 5 0 3
Adjust (Figure 69)

T h e u p p e r a n d lo w e r r e a r in t e r m e d ia t e d o o r s tr ik e r to
d o o r c l e a r a n c e s o t h a t t h e r e is 4 . 4 m m ( 0 .1 7 2 - in c h )
b e t w e e n t h e s t r ik e r a n d t h e d o o r l a t c h w h e n t h e d o o r is
Figure 69Striker Adjustments
10A1-44 DOORS
Adjust
T h e b u m p e r t o d o o r c l e a r a n c e s o t h a t t h e r e is 1 m m
(0 .0 4 -in c h ) b e tw e e n th e b u m p e r a n d th e d o o r w h e n th e
d o o r is in t h e s e c o n d a r y p o s it io n . ( T h e d o o r is l a t c h e d
b u t n o t fu lly c lo s e d ) .
DOOR TRIM PANEL

REPLACEMENT
INTERMEDIATE FRONT DOOR
D o o r s tra p .
P r y t h e l o c k k n o b o f f o f t h e l o c k r o d , w h e n t h e k n o b is
in t h e u n lo c k e d p o s it io n .
D o o r h a n d le b e z e l s c re w s .
B e z e l a n d lo c k k n o b fr o m t h e v e h ic le .
D o o r tr im p a n e l to d o o r s c r e w s ( 2 9 5 ) .
D o o r t r im p a n e l.
P u ll t h e p a n e l fr o m t h e r e t a in e r s .
R e ta in e r to d o o r s c r e w s (2 9 3 ).
R e ta in e r s fr o m th e d o o r.
312
D o o r g a r n is h m o ld in g s c r e w s ( 2 8 9 ) .
D o o r g a r n is h m o ld in g fr o m t h e d o o rs .
310
313
307.
308.
309.
310.
311.
312.
313.
314.
Bolt
Screws
B um per
Spacer
Upper Latch
Lower Latch
Screw
Drain Hole Plug

D o o r g a r n is h m o ld in g to t h e d o o r.
D o o r g a r n is h m o ld in g s c r e w s ( 2 8 9 ) .
309
R e ta in e r s to th e d o o r.
D o o r tr im p a n e l.
308
314
P u s h t h e e d g e o f t h e p a n e l in to t h e r e ta in e r s .
D o o r h a n d le b e z e l a n d lo c k k n o b to t h e v e h ic le .
F -0 0 5 0 6
P la c e th e lo c k k n o b o n to th e lo c k ro d .
D o o r h a n d le b e z e l s c re w s .
D o o r s tra p .
Figure 70Bumper Wedge Components

in t h e s e c o n d a r y l a t c h e d p o s i t i o n . ( T h e d o o r is l a t c h e d
b u t n o t f u lly c l o s e d . ) A n 11/e 4 - in c h d ia m e t e r d r ill b it m a y
b e u s e d to g a g e th is c le a r a n c e .
T h e f r o n t i n t e r m e d i a t e s t r i k e r o n t h e r e a r d o o r . A d j u s t it
s o th a t th e fr o n t d o o r lo c k p r o p e r ly e n g a g e s th e r e a r
d o o r , a n d s o t h e f r o n t d o o r is f lu s h w it h t h e r e a r d o o r .
INTERMEDIATE REAR DOORS

P u ll t h e p a n e l f r o m t h e r e ta in e r s .
S id e d o o r g a r n is h m o ld in g s c r e w s ( 3 0 4 ) a n d b o lt (3 0 2 ) .
S id e d o o r g a r n is h m o ld in g fr o m t h e d o o r.
BUMPER WEDGE
REPLACEMENT
1. B u m p e r to u p p e r a n d lo w e r d o o r fr a m e s c r e w s (3 0 8 ).
2 . B u m p e r a n d s p a c e r.

2 . B u m p e r.
3 . B u m p e r to u p p e r a n d lo w e r d o o r fr a m e s c r e w s (3 0 8 ).
R e ta in e r fr o m th e d o o r.
U p p e r d o o r g a r n is h m o ld in g s c r e w s ( 2 9 8 ) .
U p p e r d o o r g a r n is h m o ld in g fr o m t h e d o o r.

U p p e r d o o r g a r n is h m o ld in g to t h e d o o r.
U p p e r d o o r g a r n is h m o ld in g s c r e w s ( 2 9 8 ) .
R e ta in e r to th e d o o r.
S id e d o o r g a r n is h m o ld in g to t h e d o o r.
S id e d o o r g a r n is h m o ld in g s c r e w s ( 3 0 4 ) a n d b o lt ( 3 0 2 ) .
P u s h t h e e d g e o f t h e p a n e l in to t h e r e ta in e r .
DOORS 10A1-45
Figure 71Intermediate Front Door Trim Panel
WINDOW REPLACEMENT
If a g l a s s is c r a c k e d b u t s t ill i n t a c t , it s h o u l d b e
c r is s c r o s s e d w it h m a s k in g t a p e to r e d u c e t h e r is k o f in ju r y
a n d / o r d a m a g e to t h e v e h ic le . If a c r a c k e x t e n d s to t h e
e d g e o f t h e g la s s , m a r k t h e d o o r w ith a p ie c e o f c h a lk a t
t h e p o in t w h e r e t h e c r a c k m e e ts t h e w e a t h e r s tr ip . L a te r ,
w h e n e x a m in in g th e fla n g e o f th e o p e n in g fo r a c a u s e o f
th e c r a c k , s ta r t a t th e p o in t m a r k e d .
It is im p o r t a n t t h a t t h e c a u s e o f t h e c r a c k b e
d e t e r m in e d a n d t h e c o n d itio n c o r r e c te d , b e fo r e th e n e w
g la s s is in s t a lle d . T h e c a u s e o f t h e c r a c k m a y b e a n
o b s t r u c t io n o r h ig h s p o t s o m e w h e r e a r o u n d t h e f la n g e o f
t h e o p e n in g ; c r a c k in g m a y n o t o c c u r u n til p r e s s u r e fr o m
t h e h ig h s p o t o r o b s t r u c t io n b e c o m e s p a r t ic u la r ly h ig h
d u e to w in d s , e x tr e m e s o f te m p e r a tu r e , o r r o u g h te r r a in .
STATIONARY GLASS
1. W e a t h e r s t r ip s e a l b y r u n n in g a p u tty k n ife b e t w e e n t h e
fla n g e a n d th e w e a t h e r s tr ip (in s id e a n d o u ts id e th e
d o o r).
H a v e a n a s s is ta n t o u ts id e th e c a b b y th e w in d o w .
2 . W e a t h e r s t r ip a n d g la s s fr o m th e fla n g e .
F o r c e th e w e a t h e r s tr ip fr o m th e fla n g e fr o m th e
in s id e w ith a p u t t y k n ife .
3 . W in d o w fr o m t h e w e a t h e r s tr ip .

1 . W e a t h e r s t r ip to t h e g la s s .
T h e s e a m o f th e w e a t h e r s tr ip m u s t b e lo c a te d a t
t h e b o tto m c e n t e r lin e o f t h e g la s s .
2 . A s i x m m ( 1/ 4 - i n c h ) c o r d i n t h e w e a t h e r s t r i p g r o o v e . T h e
e n d s s h o u ld o v e r la p a b o u t 5 c m (6 -in c h e s ) a t th e
w in d o w b o tto m .
3 . W in d o w a n d w e a t h e r s tr ip o n th e fla n g e fr o m
th e c a b .
o u ts id e
B ru s h s o a p y w a te r o n th e fla n g e .
H a v e a n a s s is ta n t p u ll t h e c o r d fr o m in s id e t h e
c a b to s e a t t h e lip o f t h e w e a t h e r s t r ip o n t h e
fla n g e .
10A1-46 DOORS
Nut
Screw
G arnish M olding
R etainer
Screw
Bolt
Side G arnish M olding
Screw
Screw
D oor Trim Panel
F -0 0 5 0 5
Figure 72Intermediate Rear Door Trim Panel

SWING OUT WINDOW
T w i s t t h e l a t c h o n t o t h e c o v e r w i t h 1A o f a t u r n .
4 . W in d o w la tc h to d o o r s c r e w s ( 3 2 7 ) .

LOCK REPLACEMENT

1. W in d o w la tc h to d o o r s c r e w s (3 2 7 ) .
2 . W in d o w la tc h fr o m t h e w in d o w .
T w i s t t h e l a t c h 1/ 4 o f a t u r n t o r e l e a s e t h e l a t c h
c o m p o n e n t s fr o m t h e w in d o w .
L ift t h e w i n d o w f o r a c c e s s to t h e h in g e s c r e w s .
3 . H in g e to d o o r s c r e w s (3 2 0 ).
1. D o o r tr im
p a n e l.
R e fe r
2 . D o o r lo c k c o n tr o l.
R e fe r

1 . H in g e a n d h in g e s e a l to t h e d o o r.
2 . H in g e to d o o r s c r e w s (3 2 0 ).
3 . W in d o w la tc h to t h e w in d o w .
to
D o o r
D oor
T r im
Lock
P an el
C o n tro l
3 . P o w e r d o o r lo c k m o to r (if e q u ip p e d ) . R e f e r to P o w e r
4 . H in g e fr o m th e d o o r.
5 . H in g e s e a l fr o m th e d o o r.
to
D o o r L o c k M o to r R e p la c e m e n t.
4 . D o o r to r e m o te c o n tr o l s c r e w s (3 3 0 ).
5 . D o o r to lo c k s c r e w s ( 3 3 1 ).
6 . L o c k a n d r e m o te c o n tr o l w ith r o d s fr o m th e d o o r.
+ 4 -
1. L o c k a n d r e m o te c o n tr o l w ith r o d s to th e d o o r.
P la c e t h e c o v e r a n d s p a c e r th r o u g h t h e w in d o w .
2 . D o o r to lo c k s c r e w s (3 3 1 ).
P la c e th e w a s h e r a n d s p r in g o n to th e c o v e r.
3 . D o o r to r e m o te c o n tr o l s c r e w s (3 3 0 ).
DOORS 10A1-47
INTERMEDIATE FRONT
DOOR LOCK CONTROL
REPLACEMENT
1. D o o r t r im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2 . L o c k c o n tro l to d o o r s c r e w (3 3 7 ).
3 . L o c k c o n tro l fro m th e d o o r.
S lid e th e c o n tr o l to w a r d s th e fr o n t o f th e d o o r.
4 . L o c k r o d f r o m t h e lo c k c o n tr o l.
S l i d e t h e c l i p s o t h a t t h e l a r g e d i a m e t e r s l o t is in
lin e w ith t h e lo c k r o d . T h e n , p u ll t h e r o d f r o m t h e
c o n tr o l.

1. L o c k r o d to t h e lo c k c o n tr o l.
P la c e t h e r o d in to t h e c lip a n d t h e le v e r . S lid e t h e
c l ip s o t h a t t h e s m a l l d ia m e t e r s lo t is in l in e w it h
t h e lo c k ro d .
2 . L o c k c o n tro l to th e d o o r.
S lid e th e c o n tr o l to w a r d s th e r e a r o f th e d o o r.
3 . L o c k c o n tr o l to d o o r s c r e w s (3 3 7 ).
4 . D o o r tr im
p a n e l.
R e fe r
to
D o o r
T rim
P an el
DOOR LOCK CYLINDER

REPLACEMENT
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2.
L o c k c y lin d e r r e t a in in g c lip fr o m t h e c y lin d e r .
3 . L o c k c y lin d e r a n d g a s k e t fr o m th e d o o r.

1. L o c k c y lin d e r w ith g a s k e t to th e d o o r.
4.
P
D
5. D
R
6. D
R
o w e r d o o r lo c k m o to r
o o r L o c k M o to r R e p la
o o r lo c k c o n tr o l. R
e p la c e m e n t.
o o r tr im
p a n e l. R
e p la c e m e n t.
(if e q u ip p e d ) . R e f e r to P o w e r
c e m e n t.
e fe r to D o o r L o c k C o n tro l
e fe r
to
D o o r
T r im
T h e c y lin d e r r o d m u s t e n g a g e t h e lo c k a s s e m b ly
le v e r.
2 . L o c k c y lin d e r r e t a in in g c lip o n to t h e c y lin d e r .

3 . D o o r tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
P an el
DOOR OUTSIDE
HANDLE REPLACEMENT
1. D o o r t r im
p a n e l.
2.
R e fe r
to
D oo r
T r im
P an el
D o o r to o u ts id e h a n d le s c r e w s (3 4 1 ).
3 . H a n d le fro m th e d o o r.
4 . G a s k e ts fro m th e d o o r.
322. Cover
323. Spacer
325. W asher
326. Spring
327. Screw
328. Latch________________ F-00508
Figure 74Swing Out Latch Components

1. L a r g e g a s k e t o n to th e h a n d le .
10A1-48 DOORS
F-00509
Figure 75Swing Out Window Attachment
329.
330.
331.
332.
333.
334.
335.
336.
Rem ote C ontrol

B olt
B olt
Lock A sse m b ly
C lip
Rem ote C on trol Rod
Inside H andle Rod
Inside Lock Rod
Figure 76Intermediate Front Door Lock Components
DOORS 10A1-49
Figure 77Intermediate Front Door Lock Control

++
th e h a n d le .
3 . L o w e r la tc h to c o n tr o l a s s e m b ly ro d
a s s e m b ly .
INTERMEDIATE REAR DOOR

LOWER LATCH REPLACEMENT
1. D o o r
tr im
p a n e l.
R e fe r
to
D o o r
T r im
P an el
2.
th e c o n tro l
3 . L o w e r la tc h to d o o r s c r e w s ( 3 4 9 ) .
4 . L o w e r la tc h w ith t h e ro d fr o m t h e d o o r.
339.
340.
341.
342.
343.
344.
345.
346.
4. D o o r
tr im
p a n e l.
R e fe r
to
in to th e c o n tr o l
D o o r
T r im
P an el

UPPER LATCH REPLACEMENT
L o w e r la tc h to c o n tr o l a s s e m b ly ro d fr o m
a s s e m b ly .
1. L o w e r la tc h w ith th e ro d to th e d o o r.
2 . L o w e r la tc h to d o o r s c r e w s (3 4 9 ).
5 . D o o r tr im p a n e l. R e f e r to D o o r T rim P a n e l.
D o o r tr im
p a n e l.
R e fe r
to
D o o r
U p p e r la tc h to c o n tr o l a s s e m b ly ro d fr o m
T r im
P an el
th e c o n tro l
a s s e m b ly .
t h e c lip a w a y fr o m t h e r o d .
O utside Handle
Large Gasket
B olt
R etainer
Key
Lock C ylinder
Gasket
Sm all Gasket
Figure 78Outside Handle And Lock Cylinder Components
10A1-50 DOORS
8 . C o n tr o l a s s e m b ly w ith
347. Lower Latch Rod

348. Lower Latch
349. Bolt
------ 347
1 -3 4 5
F-00513
Figure 79Intermediate Rear Door Lower Latch

3 . U p p e r la tc h to d o o r b o lts ( 3 5 0 ) .
4 . U p p e r la tc h w ith t h e ro d fr o m th e d o o r.
4.
5.
6.
7.
l+il
1. U p p e r l a t c h w i t h t h e r o d t o t h e d o o r .
3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d in to t h e c o n tr o l
a s s e m b ly .
P iv o t t h e c lip o n to t h e ro d .
P an el
4 . D o o r tr im

CONTROL ASSEMBLY
REPLACEMENT
R e fe r
to
D oo r
7.
th e
access
T r im
P an el
d ia g n o s is o f t h e d o o r lo c k m o to r.
4 -+
1. B a tt e r y g r o u n d c a b le .
2 . D o o r tr im
3 . E le c tr ic a l c o n n e c t o r fr o m t h e m o to r.
T r im
P an el
4 . D o o r to m o to r s c r e w s (3 7 0 ).
5 . M o to r fr o m th e lo c k ro d .
6 . M o to r fro m th e d o o r.
T r im
P an el
lo w e r d o o r la tc h r o d s fr o m t h e c o n tr o l
a s s e m b ly .
E le c tr ic d o o r a c t u a t o r (if e q u ip p e d ) .
L o c k k n o b (3 5 6 ).
R e a r d o o r in s id e h a n d le s c r e w ( 3 6 4 ) a n d h a n d le (3 6 5 ).
R e a r d o o r lo c k ro d c lip a t t h e d o o r p a n e l.
P iv o t t h e c lip a w a y fr o m t h e r o d .
D o o r to c o n tr o l a s s e m b ly b o lts (3 6 3 ) .
2. U p p e r a n d
3.
4.
5.
6.
access
POWER DOOR LOCK

MOTOR REPLACEMENT
2. U p p e r l a t c h t o d o o r b o l t s ( 3 5 0 ) .
p a n e l.
th e
R e a r d o o r in s id e h a n d le (3 6 5 ) a n d s c r e w (3 6 4 ).
L o c k k n o b (3 5 6 ).
E le c t r ic d o o r a c t u a t o r (if e q u ip p e d ) .
U p p e r a n d lo w e r d o o r la tc h r o d s to th e c o n tr o l
a s s e m b ly .
8. D o o r tr im
|~n-| Install or Connect (Figure 80)
tr im
th ro u g h
1. C o n tr o l a s s e m b ly w ith lo c k r o d th r o u g h
h o le .
2 . D o o r to c o n tr o l a s s e m b ly b o lts (3 6 3 ).
3 . R e a r d o o r lo c k r o d c lip a t t h e d o o r p a n e l.
j o
D o o r
ro d
-------348
1.
lo c k
h o le .
350

1. M o to r in to t h e d o o r.
2 . M o to r to t h e lo c k ro d .
3 . D o o r to m o to r s c re w s (3 7 0 ).
4 . E le c tr ic a l c o n n e c to r to th e m o to r.
5 . D o o r tr im
P an el

I++I Remove or Disconnect (Figure 83)
1. W e a th e rs tr ip fro m
2.
P la s tic n a ils fr o m t h e d o o r.
jQjj Clean
350. Bolt
351. Upper Latch
352. Upper Latch Rod

F -0 0 5 1 4
Figure 80Intermediate Rear Door Upper Latch
1. W e a t h e r s t r ip a d h e s iv e to t h e d o o r .
W e a th e r s tr ip A d h e s iv e (o r e q u iv a le n t).
2 . N e w w e a t h e r s tr ip to th e d o o r.
P r e s s t h e p la s tic n a ils in to t h e d o o r.
U se
3M
DOORS 10A1-51
.353
356
357
/
355
353.
354.
355.
356.
357.
358.
359.
360.
361.
362.
363.
364.
365.
Control A ssem bly

C lip
Lock Rod
Lock Knob
Ferrule
Screw
Protector
Spring
S triker
W asher
Bolt
Screw
Handle
F-00515
Figure 81Intermediate Rear Door Control Assembly

B
1 . W e a th e r s tr ip to d o o r p a n e l s c r e w s (3 7 5 ).
1. W e a t h e r s t r i p a d h e s iv e to t h e d o o r .
W e a th e r s tr ip a d h e s iv e (o r e q u iv a le n t).
2 . N e w w e a t h e r s tr ip to th e d o o r.
P r e s s t h e p la s t ic n a ils in to t h e d o o r.
3 . W e a th e rs tr ip to d o o r p a n e l s c r e w s (3 7 5 ).
3 . P la s t ic n a ils fr o m t h e d o o r.
367
368
2 . W e a th e rs tr ip fro m
Clean
332.
367.
368.
369.
370.
Lock A ssem bly

C lip
Lock M otor Rod
Lock M otor
Screws
370
Figure 82Power Door Lock Motor Attachments
U se
3M
10A1-52 DOORS
371. W eatherstrip
372. P lastic Nail
371
F-00518
Figure 83Intermediate Front Door Weatherstrip
373. W eatherstrip
374. P lastic Nail
375. Screw
373
373
374
F-00519
Figure 84Intermediate Rear Door Weatherstrip
DOORS 10A1-53
G MODEL SLIDING SIDE DOOR
DOOR REPLACEMENT
381.
415.
416.
417.
418.
A.

U p p e r r e a r tr a c k c o v e r a n d h in g e c o v e r.
O p e n t h e d o o r c o m p le te ly .
2. U p p e r f r o n t r o l l e r a s s e m b l y ( 3 8 1 ) f r o m t h e d o o r .
M a r k t h e p o s it io n o f t h e r o lle r a s s e m b ly o n t h e
d o o r.
U p p e r re a r
U p p e r re a r
L ift t h
L o w e r fro n t
0--c=y
r I
h in g e r e t a in e r ( 3 9 3 ) f r o m t h e h in g e .
h in g e ( 3 9 4 ) fr o m t h e u p p e r r e a r tr a c k .
e h in g e o ff o f t h e tr a c k .
r o lle r ( 3 9 8 ) fr o m t h e t r a c k .
P iv o t th e d o o r a w a y
d is e n g a g e t h e r o lle r s .
6. D o o r f r o m t h e v e h i c l e .
- 4 -
Front R oller Bracket

Upper R oller
Spacer
Spring W asher
Nut
C enter The R oller
In The Track
fro m
th e
v e h ic le
F -0 0 5 2 2
to
Figure 87Upper Front Roller Components
L if t t h e h in g e r o lle r o n t o t h e t r a c k .
U p p e r r e a r h in g e r e t a in e r ( 3 9 3 ) to t h e h in g e .
D o o r to t h e v e h ic le .
U p p e r fr o n t r o lle r a s s e m b ly ( 3 8 1 ) to t h e d o o r.
L o w e r f r o n t r o lle r ( 3 9 8 ) to t h e t r a c k .
P iv o t th e d o o r a w a y fr o m th e v e h ic le to e n g a g e
t h e r o lle r s to t h e t r a c k . T h e n p iv o t t h e d o o r
to w a r d s t h e v e h ic le .
3. U p p e r rear hinge (394) to th e u p p e r rear track.
A lig n t h e r o lle r a s s e m b ly to t h e p r e v io u s ly m a d e
m a rk .
6. U p p e r r e a r t r a c k c o v e r a n d h i n g e c o v e r .
HINGE ASSEMBLY
REPLACEMENT
C lo s e t h e d o o r c o m p le te ly .
1. H i n g e c o v e r ( f i g u r e 8 5 ) .
2 . T ra c k c o v e r (fig u re 8 6 ).
3 . H in g e r e ta in e r p la te ( 3 9 3 ) .
M a r k th e p o s itio n o f th e h in g e o n th e d o o r.
N u t ( 3 9 0 ) , w a s h e r ( 3 8 9 ) , a n d r e ta in e r (3 8 0 ) .
H in g e to d o o r s c r e w (3 9 1 ).
H in g e to d o o r b o lt (3 8 8 ) .
H in g e fr o m t h e v e h ic le .

H in g e to t h e v e h ic le .
P la c e t h e r o lle r o n t h e t r a c k .
H in g e to d o o r b o lt (3 8 8 ) .
H in g e to d o o r s c r e w (3 9 1 ).
R e ta in e r (3 8 0 ), w a s h e r ( 3 8 9 ) a n d n u t (3 9 0 ).
10A1-54 DOORS
387
395
380.
387.
388.
389.
390.
391.
392.
393.
394.
395.
A.
Cover R etainer
Spring
Bolt
W asher
Nut
Screw
Bolt
R etainer
H inge A ssem bly
S triker
L u b rica tion P oints
392
380
393 A 394 A
389
390
F -0 0 5 2 3
Figure 88Upper Rear Hinge Components
UPPER FRONT ROLLER

REPLACEMENT
5 . H in g e r e ta in e r p la te (3 9 3 ).
6 . T ra c k c o v e r (fig u r e 8 6 ).
7. H in g e c o v e r (fig u r e 8 5 ).
LOWER ROLLER ASSEMBLY

REPLACEMENT
2.
3 . B r a c k e t to d o o r b o lts ( 3 8 6 ) .
M a r k th e p o s itio n o f th e a s s e m b ly to th e b r a c k e t o n th e
r o lle r a s s e m b ly .
4.
1. R o lle r a s s e m b ly to d o o r b r a c k e t b o lts (4 0 1 ).
1. R o lle r m o ld in g (if e q u ip p e d ) .
P la s tic c a p (if e q u ip p e d ) .
R o lle r fr o m th e tr a c k .
2 . C a t c h c lip ( 4 0 0 ) a n d r o d f r o m t h e c a t c h .
1. R o lle r in to t h e tr a c k .
3 . P iv o t t h e r o lle r a s s e m b ly o u t o f t h e lo w e r d o o r tr a c k .
2.
1. P iv o t t h e r o lle r a s s e m b ly in to t h e lo w e r d o o r tr a c k .
2.
B r a c k e t to d o o r b o lts (3 8 6 ) .
3 . P la s t ic c a p (if e q u ip p e d ) .
4.
R o lle r m o ld in g (if e q u ip p e d ) .
R o lle r a s s e m b ly to d o o r b r a c k e t b o lts (4 0 1 ).
DOOR ADJUSTMENT
A lig n t h e r o lle r a s s e m b ly to t h e p r e v io u s ly m a d e
m a rk .
3 . C a t c h c lip ( 4 0 0 ) a n d r o d to t h e c a t c h .
UP AND DOWN ADJUSTMENT

J -2 3 4 5 7 # 5 0 T o rx W re n c h .
1. U p p e r r e a r h in g e c o v e r.
2.
F r o n t lo c k s tr ik e r ( 4 0 4 ) .
3 . R e a r lo c k s tr ik e r ( 4 0 5 ) u s in g J - 2 3 4 5 7 .
4.
R e a r d o o r w e d g e a s s e m b ly (4 0 7 ).
Adjust (Figure 91)
Figure 89Lower Front Roller Assembly
1. T h e r e a r e d g e o f th e d o o r to o b ta in a g a p o f 4 .5 m m
0 .5 m m (0 .1 8 -in c h 0 .0 2 - in c h ) b e t w e e n t h e to p o f th e
d o o r a n d t h e r o o f s id e r a il. T h is a d ju s t m e n t s h o u ld
p r o v id e a g a p o f 6 m m
0 .5 m m ( 0 .2 5 - in c h
0 .0 2 -in c h ) b e tw e e n th e b o tto m o f th e d o o r a n d th e
r o c k e r p a n e l. T o a c c o m p lis h th is a d ju s t m e n t , lo o s e n
t h e u p p e r r e a r h in g e to d o o r b o lts ( f ig u r e 8 8 ) , a n d a lig n
th e r e a r e d g e o fth e d o o r u p o r d o w n . N e x t, tig h te n th e
u p p e r r e a r h in g e to d o o r b o lts (fig u r e 8 8 ) .
DOORS 10A1-55
2 . T h e fr o n t e d g e o f t h e d o o r b y lo o s e n in g t h e u p p e r fr o n t
r o lle r b r a c k e t to d o o r b o lts ( f ig u r e 8 7 ) a n d t h e lo w e r
h in g e to d o o r b o lts ( f ig u r e 8 9 ) . A lig n t h e d o o r to o b t a in
t h e s a m e g a p a s in s t e p 1 , t h e n t i g h t e n t h e l o w e r h i n g e
to d o o r b o lts (fig u r e 8 9 ) .
3 . T h e u p p e r fr o n t r o lle r b r a c k e t u p o r d o w n s o t h a t t h e
r o lle r is c e n t e r e d in t h e t r a c k . T h e r o lle r m u s t n o t t o u c h
t h e to p o r b o tto m o f th e tr a c k . T ig h t e n t h e u p p e r fr o n t
r o lle r b r a c k e t to d o o r b o lts ( f ig u r e 9 2 ) .
1. R e a r d o o r w e d g e a s s e m b ly (4 0 7 ).
2 . R e a r lo c k s tr ik e r ( 4 0 5 ) u s in g J - 2 3 4 5 7 .
1. R e m o v e t h e fr o n t lo c k s tr ik e r ( 4 0 4 ) .
6.
7.
8.
9.
3 . T h e g u id e o n t h e d o o r m u s t fit s n u g ly in to t h e r u b b e r
lin e d o p e n i n g in t h e s t r ik e r a s s e m b l y .
REAR STRIKER ADJUSTMENT (Figure 90)
IN AND OUT ADJUSTMENT (Figures 90 through 92)
4.
5.
1. L o o s e n t h e fr o n t la tc h s tr ik e r b o lts (4 0 3 ) .
2 . S l id e t h e d o o r t o w a r d s t h e s tr ik e r .
5 . T ig h t e n t h e s tr ik e r b o lts ( 4 0 3 ) .
3 . F r o n t lo c k s tr ik e r ( 4 0 4 ) .
4 . U p p e r r e a r h in g e c o v e r.
3.
FRONT STRIKER ADJUSTMENT (Figure 90)
4 . C h e c k t h a t t h e la t c h f u lly e n g a g e s t h e s t r ik e r . A d d o r
d e le t e s h im s b e h in d t h e s tr ik e r to a c c o m p lis h th is
a d ju s tm e n t.
2 . L o o s e n th e n u t (4 1 8 ) r e ta in in g
7. In s ta ll th e u p p e r fr o n t tr a c k c o v e r.
8 . In s ta ll t h e fr o n t ( 4 0 4 ) a n d r e a r ( 4 0 5 ) lo c k s t r ik e r s a t t h e
p o s itio n p r e v io u s ly m a r k e d (fig u r e 9 0 ).
th e
J -2 3 4 5 7 W re n c h .
1 . L o o s e n t h e s tr ik e r u s in g J - 2 3 4 5 7 .
u p p e r f r o n t r o lle r
( 4 1 5 ) to t h e u p p e r r o lle r b r a c k e t ( 3 8 1 ) .
L o o s e n th e lo w e r fr o n t r o lle r a s s e m
a s s e m b ly b r a c k e t b o lts (fig u r e 8 9 ) .
L o o s e n t h e r e a r d o o r lo c k s tr ik e r .
A d ju s t t h e d o o r in o r o u t u n til t h e s u r f a c e
flu s h w ith th e s u r fa c e o f th e b o d y .
T ig h t e n t h e r e a r d o o r lo c k s tr ik e r .
T ig h t e n t h e lo w e r fr o n t r o lle r a s s e m
a s s e m b ly b r a c k e t b o lts (fig u r e 8 9 ).
T ig h t e n t h e n u t (4 1 8 ) r e ta in in g t h e u p p
(4 1 5 ) to t h e u p p e r r o lle r b r a c k e t ( 3 8 1 ) .
In s t a ll t h e f r o n t lo c k s tr ik e r .
b ly
to
r o lle r
o f t h e d o o r is
b ly
to
r o lle r
2 . L o o s e n th e r e a r w e d g e a s s e m b ly .
3 . C e n t e r t h e s tr ik e r v e r t ic a lly s o t h a t t h e s tr ik e r p r o p e r ly
e n g a g e s t h e d o o r lo c k . M a r k t h e v e r tic a l p o s itio n o f t h e
s tr ik e r .
4 . A d j u s t t h e s t r ik e r in o r o u t t o a l ig n t h e s u r f a c e o f t h e
d o o r flu s h w ith th e b o d y s u r fa c e . M a r k t h e p o s itio n o f
t h e s tr ik e r .
5 . T ig h t e n t h e s tr ik e r u s in g J - 2 3 4 5 7 .
6 . O p e n t h e d o o r , a n d a p p ly g r e a s e to t h e s tr ik e r .
e r f r o n t r o lle r
FORWARD AND REARWARD ADJUSTMENT

1 . M a r k t h e p o s itio n o f t h e fr o n t a n d r e a r la tc h s tr ik e r s o n
t h e b o d y p illa r s .
2 . R e m o v e t h e fr o n t ( 4 0 4 ) a n d r e a r ( 4 0 5 ) lo c k s tr ik e r s
(fig u re 9 0 ).
3 . R e m o v e th e u p p e r fro n t tr a c k o v e r.
4 . L o o s e n t h e u p p e r r e a r h in g e s tr ik e r (fig u r e 8 8 ).
5 . A d ju s t th e d o o r fo rw a rd o r r e a r w a r d to o b ta in a g a p o f
4 .5 m m 0 .5 m m (0 .1 8 -in c h 0 .0 2 -in c h ) b e t w e e n t h e
le ft a n d r ig h t d o o r e d g e a n d t h e d o o r p illa r s ( f ig u r e 9 1 ).
6 . T ig h t e n t h e u p p e r r e a r h in g e s tr ik e r (fig u r e 8 8 ).
7. C lo s e th e d o o r to m a k e a n im p r e s s io n o f th e lo c k o n
t h e s tr ik e r .
8 . O p e n th e d o o r a n d m e a s u r e th e d is ta n c e fr o m th e r e a r
o f t h e s tr ik e r h e a d to t h e im p r e s s io n . T h e d is t a n c e
s h o u ld b e b e tw e e n 5 m m a n d 8 m m (0 .2 0 -in c h a n d
0 .3 0 -in c h ).
9 . A d ju s t t h e s tr ik e r b y a d d in g o r d e le t in g s h im s . A lig n
t h e s tr ik e r to t h e p r e v io u s ly m a d e m a r k s .
1 0 . T ig h t e n t h e s t r ik e r u s in g J - 2 3 4 5 7 .
UPPER REAR HINGE ADJUSTMENT (Figure 93)

1. T h e lo w e r h in g e le v e r (4 1 9 ) s h o u ld h a v e a g a p o f 2 .5
m m to 4 m m (0 .1 0 -in c h to 0 .1 6 -in c h ) b e tw e e n th e o u te r
e d g e o f t h e lo w e r le v e r a n d t h e s tr ik e r la tc h e d g e . T h is
a d j u s t m e n t is m a d e
b y a d d in g
an
equal am ount of
10A1-56 DOORS
DOORS 10A1-57
381. Front R oller

Assem bly
382. M olding
383. Screw
384. Screw
385. Cap
386. Bolt
F-01401
Figure 92Upper Front Roller Adjustment

s h im s b e t w e e n
a s s e m b ly ,
a s s e m b ly .
and
th e g u id e
b e tw e e n
b lo c k ( 4 2 0 ) a n d
th e
r o lle r
and
th e
th e
h in g e
h in g e
2 . A d ju s t t h e s t r ik e r u p o r d o w n to o b t a in a g a p o f 1 .5 m m
( 0 .0 6 -in c h ) b e t w e e n t h e lo w e r e d g e o f th e s tr ik e r p la t e
( 3 9 5 ) a n d t h e lo w e r e d g e o f t h e lo w e r h in g e le v e r (4 1 9 ).
3 . A d ju s t th e g u id e u p o r d o w n to o b ta in a g a p o f 0 .5 m m
(0 .0 2 -in c h ) b e tw e e n th e tr a c k a n d th e g u id e .
DOOR HOLD OPEN CATCH ADJUSTMENT (Figure 89)

1. M a r k t h e p o s it io n o f t h e lo w e r r o lle r a s s e m b ly to t h e
b ra c k e t.
2 . L o o s e n t h e lo w e r r o lle r a s s e m b ly b o lts ( 4 0 1 ) .
3 . P iv o t t h e lo w e r r o lle r a s s e m b ly to p r o p e r ly e n g a g e t h e
la t c h s tr ik e r .
4 . T ig h t e n t h e lo w e r r o lle r a s s e m b ly b o lts ( 4 0 1 ) .
REAR WEDGE ASSEMBLY ADJUSTMENT (Figure 94)

1. L o o s e n th e r e a r w e d g e a s s e m b ly s c re w s (4 0 8 ).
2 . C o m p le te ly c lo s e th e d o o r.
3 . F r o m in s id e t h e v e h ic le , c e n t e r t h e w e d g e a s s e m b ly
(4 0 7 ) o n to th e d o o r w e d g e .
4 . M a r k th e p o s itio n o f th e w e d g e a s s e m b ly .
5 . O p e n th e d o o r, a n d m o v e th e w e d g e a s s e m b ly fo rw a rd
4 . 7 m m ( 3/ i e - i n c h ) .
6 . T ig h t e n t h e r e a r w e d g e a s s e m b ly s c r e w s ( 4 0 8 ) .
394.
395.
419.
420.
421.
A.
B.
C.
H inge A ssem bly

S trike r
Lower H inge Lever
G uide Block
Track
2.5 mm to 4 mm (0.10- inch to 0.16-inch)
1.5 mm (0.06-inch)
0.5 mm (0.02-inch)
F-00539
Figure 93Upper Rear Hinge Adjustments
10A1-58 DOORS
430
422.
423.
424.
425.
426.
427.
428.
429.
430.
422
423
Inside Handle
A s s is t Strap
Door Trim Panel
Screw
Cover
Screw
Lock Knob
Screw
Cover
424
-425
426
427
429 428
F-00541
DOOR TRIM PANEL

REPLACEMENT
1. Inside door handle screw (429).
2. Inside door handle (422).
3. Inside door handle cover (430).
4. Lock knob (428).
Pull the knob from the door.
5. Door assist strap screws (425), and assist strap (423).
6. Trim panel to door screws (427).
7. Trim panel from the door.

1. Trim panel to the door.
2. Trim panel to door screws (427).
3. Door assist strap (423) and assist strap screws (425).
4. Lock knob (428).
5. Inside door handle cover (430).
6. Inside door handle (422).
7. Inside door handle screw (429).
WINDOW REPLACEMENT
If a glass is cracked but still intact, it should be
crisscrossed with masking tape to reduce the risk of injury
and/or damage to the vehicle. If a crack extends to the
edge of the glass, mark the door with a piece of chalk at
the point where the crack meets the weatherstrip. Later,
when examining the flange of the opening for a cause of
the crack, start at the point marked.
It is important that the cause ofthe crack be determined
and the condition corrected, before the new glass is
installed. The cause of the crack may be an obstruction or
high spot somewhere around the flange of the opening;
cracking may not occur until pressure from the high spot
or obstruction becomes particularly high due to winds,
extremes of temperature, or rough terrain.
STATIONARY GLASS
1. Weatherstrip seal by running a putty knife between the
flange and the weatherstrip (inside and outside the
door).
Have an assistant outside the cab by the window.
2. Weatherstrip and glass from the flange.
Force the weatherstrip from the flange from the
inside with a putty knife.
3. Window from the weatherstrip.
Install or Connect
1. Weatherstrip to the glass.
The seam of the weatherstrip must be located at
the bottom of the glass.
2. Asix mm (1/4-inch) cord in the weatherstrip groove. The
ends should overlap about 5 cm (6-inches) at the
window bottom.
3. Window and weatherstrip on the flange from outside
the cab.
Have an assistant pull the cord from inside the
cab to seat the lip of the weatherstrip on the
flange.
SWING OUT WINDOW

1. Window latch to door screws (441).
2. Window latch from the window.
Twist the latch 1At of a turn to release the latch
components from the window.
Lift the window for access to the hinge screws.
3. Hinge to door screws (435).
DOORS 10A1-59
FRONT LOCK REPLACEMENT
4. Hinge from the door.

5. Hinge seal from the door.

1. Hinge and hinge seal to the door.
2. Hinge to the door screws (435).
3. Window latch to the window.
Place the cover and spacer through the window.
Place the washer and spring onto the cover.
Twist the latch onto the cover with 1/4 of a turn.
434.
435.
436.
437.
438.
G lass
Screw
H inge
W eatherstrip
Cover
439.
440.
441.
442.
443.
Spacer
W asher
Screw
Latch
Spring
1. D oor trim p a n e l. R efer to D oor Trim Panel

Replacement.
2. Lock access panel screws (445) and the panel (444).
Pull the panel upwards to disengage the clips.
3. Outside door handle (422).
4. Lock to door screws (449 and 451).
5. Rear door lock rods from the front lock.
Pivot the clips from the rods, and pull the rods
from the lock.
6. Lower latch rod from the lock.
Pivot the clip from the rod and pull the rod from
the lock.
437
435
436
434
438
439
440
441
442
F-00543
Figure 97Swing Out Window Components
10A1-60 DOORS
Figure 98Door Lock Access Panel
Figure 99Door Lock Attachment
DOORS 10A1-61
447.
448.
454.
455.
456.
457.
458.
459.
Upper Lock Rod

Lower Lock Rod
Latch Rod R etainer
C lip
Rear Lock A sse m b ly
Screw
Bum per
Screw
448
F-00546
Figure 100Rear Lock Attachment

7. Lock cylinder rod clips.
Slide the clip to release the rod.

8 Lock assembly from the door.

1. Lock assembly to the door.
2. Lock cylinder rod clip.
3. Lower latch rod to the lock.
Pivot the clip onto the rod:
4. Rear door lock rods to the front lock.
Pivot the clip onto the rod.
5. Lock to door screws (449 and 451).
6. Outside door handle (422).
7. Lock access panel (444) and panel screws (445).
Replacement.
REAR LOCK REPLACEMENT

1. Lock rods from the lock.
Pivot the clip from the rod, and pull the rod from
the lock.
2. Lock to door screws (457).
3. Lock from the door through the access hole.

1. Lock to the door through the access hole.
2. Lock to door screws (457).
3. Lock rods to the lock.
LOCK CYLINDER
REPLACEMENT
Replacement.
2. Door lock cylinder rod (450).
3. Cylinder retainer (462).
Pry the retainer from the lock.
4. Cylinder (464) and seal (463) from the door.

1. Cylinder (464) and seal (463) to the door.
2. Cylinder retainer (462).
Push the retainer onto the cylinder.
3. Door lock cylinder rod (450).
Replacement.
SLIDING SIDE DOOR

1. Weatherstrip from the door using 3M Release Agent
(or equivalent).
2. Plastic nails from the door.
The door of all the old cement.
10A1-62 DOORS
460
450.
460.
461.
462.
463.
464.
465.
Lock C ylin d e r Rod

O utsid e H andle
W asher
Retainer
G asket
C ylind e r
Key
F-00547
Figure 101Outside Handle and Lock Cylinder Attachments

1. W e a th e rs trip a d h e s iv e to the door.
Weatherstrip Adhesive (or equivalent).
2. New weatherstrip to the door.
Press the plastic nails into the door.
Use 3M
DOORS 10A1-63
466. W e a th e rs trip
467. P la s tic N a ils
F-00548
Figure 102Sliding Side Door Weatherstrip
G MODEL REAR DOORS

DOOR AND HINGE
REPLACEMENT

Open the doors.
1. Electrical wiring harness (if equipped). Refer to Door
Trim Panel Replacement for access to the wiring
harness.
Mark the position of the door on the hinges using a
wax pencil.
2. Strap pin (469).
Support the door.
3. Hinge to body pillar bolts (475).
4. Door from the vehicle.
5. Hinge to door bolts (470).
6. Hinges from the door.
7. Retainers (478), seals (477), and grommets (479) from

the door or the hinges.

1. Grommet to the door.
2. Hinge to the door.
3. Hinge to door bolts (470).
Align the hinge to the previously made mark.
4. The seals and retainers to the body half of the hinge.
5. Door to the vehicle.
Support the door.
6. Hinge to body pillar bolts (475).
Align the hinge to the previously made mark.
7. Strap pin (469).
8. Electrical wiring harness.
Refer to Door Trim Panel Replacement for
access to the wiring harness.
10A1-64 DOORS
DOOR ADJUSTMENT
Each of the two doors must first be adjusted in the door
opening before adjusting the door to door clearance.
Adjust (Figure 104)

1. The door height so that there is a gap of 6 mm 0.5
mm (0.25-inch 0.02-inch) between the roof panel and
the rear door panel.
2. The gap between the bottom of the door panel (not the
bottom of the outer panel) and the platform panel
should be 6 mm 0.5 mm (0.25-inch 0.02-inch).
This measurement should be taken on each door
individually from the side of the door. Thedoor should
be in its normal closed position. (The outer rear door
panel is 15.25 mm 0.5 mm (0.60-inch 0.02-inch)
away from the rear platform panel when normally
closed).
3. The rear door outer panel to the body side outer panel
gap to 4 mm 0.5 mm (0.16-inch 0.02-inch).
4. The door to door clearance between the left and right
outer door panels should be 6 mm 0.5 mm
(0.25-inch 0.02-inch).
++
1. Spacer (as required).

2. Striker to the door frame.
3. Striker to door frame bolts (486).
ft
A djust (Figure 106)
The striker to door latch clearance so that there are 4.4

mm (0.172-inch) between the striker and the door latch
when the door is in the secondary latched position.
(The door is latched but not fully closed.) An 11/e4-inch
diameter drill bit may be used to gage this clearance.
DOOR TRIM PANEL

REPLACEMENT
|+"*| Remove or Disconnect (Figure 107)
1. Door trim panel to door screws (489).
2. Door trim panel from the vehicle.
Slide the panel out of the retainers.
STRIKER REPLACEMENT
1. Striker to door frame bolts (486).
2. Striker from the door frame.
3. Spacer (if equipped).

1. Door trim panel to the vehicle.
Slide the panel into the retainers.
2. Door trim panel to door screws (489).
DOORS 10A1-65
485
Roof Panel
Roof Side Rail
Left Door
Right Door
Body Side Panel
Floor E xtension Panel
6 mm 0.5 mm (0.25-inch 0.02-inch)
B. 15.25 mm 0.5 mm (0.60-inch 0.02-inch)
C. 4 mm 0.5 mm (0.16-inch 0.02-inch)
F-00550
10A1-66 DOORS
3. Bumper to upper door frame screws (495).
Adjust
The bumper to door clearance so that there is 1 mm
(0.04-inch) between the bumper and the door when the
door is in the secondary position. (The door is latched
but not fully closed).
WINDOW REPLACEMENT
If a glass is cracked but still intact, it should be
crisscrossed with masking tape to reduce the risk of injury
and/or damage to the vehicle. If a crack extends to the
edge of the glass, mark the door with a piece of chalk at
the point where the crack meets the weatherstrip. Later,
when examining the flange of the opening for a cause of
the crack, start at the point marked.
It is im p o rta n t th a t th e c a u s e of th e c ra c k be
determined and the condition corrected, before the new
glass is installed. The cause of the crack may be an
obstruction or high spot somewhere around the flange of
the opening; cracking may not occur until pressure from
the high spot or obstruction becomes particularly high
due to winds, extremes of temperature, or rough terrain.

BUMPER WEDGE
REPLACEMENT
1. Using a 3/ie-inch drill bit, drill the rivets from the

weatherstrip (if equipped).
|<*+| Remove or Disconnect (Figure 108)
2. Weatherstrip seal by running a putty knife between the

flange and the weatherstrip (inside and outisde the
door).
1. Bumper to upper door frame screws (495).

2. Bumper and spacer.
El
Have an assistant outside the cab by the window.
3. Weatherstrip and glass from the flange.
1. Spacer (as required).

2. Bumper.
Force the weatherstrip from the flange from the

inside with a putty knife.
488.
4. Window from the weatherstrip.
|+ + | Install or Connect (Figure 109)
487486.
487.
488.
A.
"S '
1. Weatherstrip to the glass.

2. A six mm (1/4-inch) cord in the weatherstrip groove. The
ends should overlap about 5 cm (6-inches) at the
window bottom.
B olt
\
S trike r
486
Spacer
4.4 mm
(0.172-inch)
3. Window and weatherstrip on the flange from outside

the cab.
486

Have an assistant pull the cord from inside the
cab to seat the lip of the weatherstrip on the
flange.
...
Figure 106Striker Components
F-00552
4. Rivets (if equipped) to the weatherstrip with a rivet gun.

Use 3/ie-inch blind rivets.
DOORS 10A1-67
489.
490.
491.
492.
493.
494.
Screw
D oor Trim Panel
Side R etainer
Screw
Side R etainer
Top Retainer
F-00553
SWING OUT WINDOW

2. Window latch from the window.
Twist the latch 1/4 of a turn to release the latch
components from the window.
Lift the window for acess to the hinge screws.
4. Hinge from the door.
5. Hinge seal from the door.
496

1. Hinge and hinge seal to the door.
3. Window latch to the window.
Place the cover and spacer through the window.
Place the washer and spring onto the cover.
Twist the latch onto the cover with 1/4 of a turn.
LEFT DOOR LOWER

LATCH REPLACEMENT
Open the door.
1. Latch to door screws (511).
2. Latch from the door.

1. Latch to the door.
2. Latch to door screws (511).
RIGHT DOOR LOWER

LATCH REPLACEMENT
Figure 108Bumper Wedge Components
1. D oor trim p a n e l. R e fe r to D oor Trim Panel

Replacement.
2. Lower latch to control assembly rod from the control
assembly.
10A1-68 DOORS
510
510
509
507
508
501
504
501.
502.
503.
504.
505.
506.
507.
508.
509.
510.
W eatherstrip
Screw
Latch A ssem bly
Cover
W indow
Spacer
W asher
S pring
Screw
H inge
506
502
510
505
503
505
F-00556
Figure 110Swing Out Window Components
DOORS 10A1-69
Using a flat bladed screwdriver, push on the top

of the clip where it is connected to the rod. Pivot
the clip away from the rod.
3. Lower latch to door screws (513).
4. Lower latch with the rod from the door.
Figure 113Right Door Upper Latch

3. Upper latch to door bolts (517).

Lower latch with the rod to the door.
2. Lower latch to door screws (513).
3. Lower latch to control assembly rod into the control
assembly.
Replacement.
4. Upper latch with the rod from the door.

1. Upper latch with the rod to the door.
2. Upper latch to door bolts (517).
3. Upper latch to control assembly rod into the control
assembly.
RIGHT DOOR UPPER

LATCH REPLACEMENT

Replacement.

D oor trim p a n e l. R e fe r to D oor Trim Panel
Replacement.
Upper latch to control assembly rod from the control
assembly.
513.
514.
515.
516.
S cre w
L o w e r Latch
L o w e r L ock Rod
D rain H ole C lip
RIGHT DOOR CONTROL

Replacement.
2. Upper and lower door latch rods from the control
assembly.
3. Electric door actuator (if equipped).
4. Door to control assembly bolts (520).
5. Control assembly through the access hole.
514

1. Control assembly through the access hole.
513
2. Door to control assembly bolts (520).

3. Electrical door actuator (if equipped).
4. Upper and lower door latch rods to the control
assembly.
F-00558
Figure 112Right Door Lower Latch
Pivot the clips onto the rods.

Replacement.
10A1-70 DOORS
111 Install or Connect (Figure 115)

1. Large gasket onto the handle.
2. Door to outside handle screw (502) to the push button

side of the handle.
Do not tighten.
3. Small gasket between the door and the handle.
4. Door to outside handle screw (522) to the other side of
the handle.
Tighten both screws.
5. Door trim panel. Refer to Door Trim Panel.
DOOR LOCK CYLINDER

REPLACEMENT
I++I Remove or Disconnect (Figure 115)
1. D oor trim p a n e l. R efer to D oor Trim
Replacement.
Panel
2. Lock cylinder retaining clip from the cylinder.

Slide the clip off the cylinder with a screwdriver.
3. Lock cylinder and gasket from the door.

1. Lock cylinder with gasket to the door.
The cylinder rod must engage the lock assembly
lever.
Figure 114Right Door Control Assembly

Attachment
DOOR OUTSIDE HANDLE

REPLACEMENT
M
Remove or D isconnect (Figure 115)

Replacement.
2. Door to outside handle screws (502).
3. Handle from the door.
4. Gaskets from the door.
2. Lock cylinder retaining clip onto the cylinder.

Replacement.
CHECK STRAP REPLACEMENT

1. Pin (469).
2. Strap to door bolts (474).
3. Strap (472).
4. Bracket to inner panel bolts (471).
5. Bracket (473).
523
522
522.
523.
524.
525.
526.
527.
528.
529.
524
Screw
Sm all G asket
O utsid e Handle
Key
Lock C ylin d e r
Large G asket
Retainer
G asket
525
F-00561
Figure 115Outside Handle and Lock Cylinder Attachments
DOORS 10A1-71
530.
531.
532.
533.
534.
Pin
C h e ck A s s e m b ly
B o lt
B o lt
B ra cke t
530
534
533
532
535. F a ste n e r
537. P la s tic N ail
F-00562
Figure 116Check Assembly Components

1. Bracket (473).
3. Strap to the door.
F-00563
4. Strap to door bolts (474).
Figure 117Left Door Weatherstrip
5. Pin (469).
LEFT DOOR WEATHERSTRIP

REPLACEMENT
CHECK ASSEMBLY
REPLACEMENT
1. Pin (530).
2. Check assembly to door bolts (532).
3. Check assembly (531).
5. Bracket (534).

Tool Required:
J-24595-B Door Trim Pad Clip Remover.
1. Weatherstrip to door fasteners using J-24595-B.
(or equivalent).
3. Plastic nails from the door frame.
jQ|[ Clean
The door and weatherstrip of all the old cement.
1. Bracket (534).
3. Check assembly (531).
4. Check assembly to door bolts (532).
5. Pin (530).

1. New weatherstrip to the door using 3M Weatherstrip
Adhesive (or equivalent).
Push the plastic nails into the door frame.
2. Weatherstrip to door fasteners.
10A1-72 DOORS
POWER DOOR LOCK
MOTOR REPLACEMENT
Replacement.
3. Electrical connector from the motor.
4. Door to motor screws (540).
5. Motor from the lock rod.
Slide the rubber mount at the top of the motor off
of the door lock rod.
6. Motor from the door.
1. Motor into the door.

2. Motor to the lock rod.
Slide the rubber mount at the top of the motor
onto the door lock rod.
3. Door to motor screws (540).
4. Electrical connector to the motor.
Replacement.
539. P la s tic N ail
F-00564
Figure 118Right Door Weatherstrip
RIGHT DOOR WEATHERSTRIP

REPLACEMENT
(or equivalent).
2. Plastic nails from the door frame.
Clean
The door and weatherstrip of all the old cement.
1. New weatherstrip to the door using 3M Weatherstrip

Push the plastic nails into the door frame.
DOORS 10A1-73
Figure 119Power Door Lock Motor Attachment
10A1-74 DOORS
SPECIAL TOOLS
1.
2.
____________ J-22585-01
jm rr r7 Z S
J-23457-A
3. f*>)------------------------------ ----
4./i
r------- --------- *
1. D o o r H in g e B o lt W re n ch
3. D o o r H a n d le C lip R em ove r
2. D o o r S trik e r W re n ch
4. D o o r Trim Pad C lip R em ove r
J-9886-01
J-24595-B
F-02460
10A2-1
SECTION 10A2
SEATS
NOTICE: All seat belt fasteners are important attaching parts in that they could affect the performance of all vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part
of all parts.
CONTENTS
SUBJECT
PAGE
Diagnosis Of Manual Seat A djuster....................................................................................................................... 10A2- 2

Seat Adjuster Adjustm ent................................................................................................................................... 10A2- 3
RV Model Front Seat................................................................................................................................................10A2- 3
Front Seat And Seat Adjuster Replacement.....................................................................................................10A2- 3
Utility Vehicle Passenger Front Bucket Seat Replacement............................................................................ 10A2- 3
Front Pivot Bracket Disassembly....................................................................................................................... 10A2- 3
Bench Seatback And Catch Replacement.........................................................................................................10A2- 5
Seat Belt Replacement........................................................................................................................................10A2- 6
High Back Bucket Seat Belt Replacement.........................................................................................................10A2- 7
RV Model Suburban Center S eat........................................................................................................................... 10A2- 8
Center Seatback Replacement........................................................................................................................... 10A2- 8
Center Seat Bottom Replacem ent............................................................................................... ...................10A2- 8
Center Seat Bottom Support Bracket Replacement........................................................................................ 10A2- 8
Center Seatback Bumper And Striker Replacement........................................................................................ 10A2- 9
Center Seat Bottom Striker Replacement.........................................................................................................10A2- 9
Center Seatback Latch Replacement................................................................................................................. 10A2- 9
Center Seat Bottom Latch Replacement...........................................................................................................10A2- 9
Center Seat Belt Replacement........................................................................................................................... 10A2-11
RV Model Rear S e a ts ..............................................................................................................................................10A2-13
Crew Cab Rear Seat Replacement..................................................................................................................... 10A2-13
Crew Cab Rear Seatback And Catch R eplacem ent........................................................................................ 10A2-13
Crew Cab Rear Seat Belt Replacement.............................................................................................................10A2-13
Utility Vehicle Rear Seat Replacem ent................................................... ......................................................10A2-14
Utility Vehicle Rear Seat Cover Rod Replacement.......................................................................................... 10A2-14
Utility Vehicle Rear Seat Storage Strut Replacem ent.................................................................................... 10A2-14
Utility Vehicle Rear Seat Belt R eplacem ent.....................................................................................................10A2-14
Utility Vehicle And Suburban Seatback And Hinge Replacement..................................................................10A2-16
Utility Vehicle And Suburban Latch And Support Assembly Replacement................................................. 10A2-16
Suburban Rear Seat Replacement..................................................................................................................... 10A2-17
Suburban Rear Seat Belt Replacement............................................................................................................. 10A2-18
RV Model Top Strap Belt Anchor Installation.......................................................................................................10A2-19
Pickup And Crew Cab M o d e ls ........................................................................................................................... 10A2-19
Utility Vehicle Rear S e a t......................................................................................................................................10A2-19
Suburban Front S eat............................................................................................................................................10A2-19
Suburban Second S e a t........................................................................................................................................10A2-21
Suburban Third S e a t............................................................................................................................................10A2-21
G Model Front S eat..................................................................................................................................................10A2-23
Front Seat Replacement......................................................................................................................................10A2-23
Front Seat D isassem bly......................................................................................................................................10A2-23
Front Seat Belt Replacement............................................................................................................................. 10A2-23
10A2-2 SEATS
SUBJECT
PAGE
G Model Center And Rear S e a ts ............................................................................................................................10A2-26

Center And Rear Seat R eplacem ent................................................................................................................. 10A2-26
Center And Rear Seat Disassembly....................................................................................................................10A2-26
Center And Rear Seat Armrest Replacement................................................................................................... 10A2-27
Center And Rear Seat Belt Replacement.................................................................. .........................................10A2-27
G Model Top Strap Belt Anchor Installation......................................................................................................... 10A2-30
Vehicles With A 125-Inch W heelbase............................................................................................................... 10A2-30
Vehicles With A 110-Inch W heelbase............................................................................................................... 10A2-31
S pe cifica tio ns...........................................................................................................................................................10A2-34
DIAGNOSIS OF MANUAL SEAT ADJUSTER

PROBLEM
Adjuster Will Not Lock
POSSIBLE CAUSE
1. Locking wire too tight.
2. Adjuster lock bar spring disconnected or

broken.
3. Adjuster lock bar sticking or binding.
Adjuster Will Not

Unlock
1. Locking wire too loose or disconnected.
2. Adjuster lock bar sticking or binding.
CORRECTION
1. L o o s e n th e lo c k in g w ire te n s io n
enough to provide full engagem ent of
the lock bar in the locking slots of the
adjuster lower channel. Refer to Seat
Adjuster A djustm ent.
2. Connect the spring or install a new
spring.
3. Lubricate the lock bar pivot. If the bar is
binding, elim inate the cause of binding
or replace the adjuster.
1. Tighten the locking wire enough to al
low the lock bar to disengage from the
locking slots in the adjuster lower chan
nel when the lock control lever is ac
tiv a te d . R e fe r to S e a t A d ju s te r
Adjustm ent.
2. Lubricate the lock bar pivot. If the bar is
binding, elim inate the cause of binding
or replace the adjuster.
When The Left

Adjuster Locks, The
Right Adjuster Is
Between Lock
Positions
1. Right adjuster either rearward or forward

of the left adjuster.
1. Loosen the adjuster to floor pan bolts

or nuts move one adjuster forward or
rearward as far as possible and the
other adjuster in the opposite direction.
Refer to Seat Adjuster Adjustm ents.
Seat Hard To Move

Forward Or Rearward
1. Adjusters new, not broken in.
1. Operate the seat to the full forward and

full rearward positions several tim es to
work the new tightness out of the chan
nels.
2. Lubricate the adjuster channels with
Lubriplate or equivalent.
3. Replace the adjuster.
2. Adjuster(s) improperly lubricated.

3. Adjuster(s) binding due to bent or dam
aged channels.
4. Adjusters not in parallel alignm ent with
each other.
4. Loosen the floor pan attaching bolts or

nuts, align the adjusters parallel on the
floor pan and tighten nuts. Refer to
Seat Adjuster Adjustm ents.
SEATS 10A2-3
SEAT ADJUSTER
ADJUSTMENT
Adjust
Remove the seat. Refer to Front Seat and Seat
Adjuster Replacement.
Leave the adjuster on the seat.
Loosen the adjuster to seat bolts.
1. The adjuster rails forward or rearward so that both rails
are the same distance from the front of the seat.
2. The adjuster rails so they are parallel to each other.
Tighten the adjuster to seat bolts.
3. Wire assembly tension. Three holes on the secondary
adjuster rail allow for tension adjustment of the wire
assembly (figure 1).
Slide the spring off of the hook.
Open the hook, and remove it from the hole.
Move the hook to a forward hole to loosen the
wire, move the hook to a rearward hole to tighten
it.
Close the hook, and slide the spring over the

hook.
Install the seat. Refer to Front Seat and Seat Adjuster
Replacement.
RV MODEL FRONT SEATS

FRONT SEAT AND SEAT
ADJUSTER REPLACEMENT
This procedure applies to all RV Model front seats,
w hether bench or bucket type with the exception of the
utility vehicle passenger front bucket seat. Refer to
U tilit y V e h ic le P a s s e n g e r F ro n t B u c k e t S e a t
Replacem ent for information on this type of seat.

1.
2.
3.
4.
5.
Bolt cover (5) (if equipped).

Seat adjuster to floor panel bolts (7).
Seat (10) with adjuster (2) from the vehicle.
Adjuster to seat bolts (8).
Adjuster (2) from the seat (10).
E
1.
2.
3.
4.
5.
7. Latch assembly to seat bolts.

8. Latch assembly from the seat.

1.
2.
3.
4.
5.
6.
7.
Latch assembly to the seat.

Latch assembly to seat bolts.
Seat brackets (14) to the seat.
Upper seat bracket bolts (15).
Seat to the vehicle.
Lower seat bracket (22) to the floor panel bolts (20).
Spring retaining bracket (13) onto the springs (21), and
the spring retaining bracket bolts (12).
8. Restraint cable (19) to the floor panel bolts (22).
FRONT PIVOT BRACKET

DISASSEMBLY

Adjuster (2) to the seat (10).
Adjuster to seat bolts (8).
Seat (10) with adjuster (2) to the vehicle.
Seat adjuster to floor panel bolts (7).
Bolt cover (5) (if equipped).
UTILITY VEHICLE
PASSENGER FRONT BUCKET
SEAT REPLACEMENT
Place the seat in its forward position.
1. Restraint cable (19) to the floor panel bolt (22).
Allow the seat to tip forward.
2. Spring retaining bracket bolts (12) and the bracket (13).
3. Lower seat bracket (23) to the floor panel bolts (20).
4. Seat from the vehicle.
5. Upper seat bracket bolts (15).
6. Seat brackets (14) from the seat.
This procedure applies only to Utility Vehicle passenger

front bucket seats.

1. Seat. Refer to Utility Vehicle Passenger Front Bucket
Seat Replacement.
2. Nut (18).
3. Washer (17).
4. Pivot stud (25).
5. Sleeve (24).
6. Springs (21).
7. Upper bracket (14) from the lower bracket (23).

1.
2.
3.
4.
5.
6.
Upper bracket (14) to the lower bracket (23).

Springs (21) onto the sleeve (24).
Brackets (14 and 16) to the sleeve.
Pivot stud (25).
Washer (17).
Nut (18).
Tighten each nut until it bottoms out.
10A2-4 SEATS
Figure 3Bucket Seat Components
SEATS 10A2-5
14
11. Seat
12. B o lt
13. S p rin g R e ta in in g
B ra cket
14. U p p e r B ra cke t
15. B o lt
16. B o lt
17. W a sh er
18.
19.
20.
21.
22.
23.
24.
25.
N ut
C able
B o lt
S p rin g
B o lt
L ow er B ra cket
Sleeve
P ivot S tud
F-00589
Figure 4Utility Vehicle Passenger Seat Components

7. Seat. Refer to Utility Vehicle Passenger Front Bucket
Seat Replacement.
BENCH SEATBACK AND

CATCH REPLACEMENT
1. Seat back trim cover (32).
2. Striker (27).
3. Catch (28) with bushing (29).
4. Washer (30).
5. Seatback to seat base bolt (26).
6. Washer (30).
7. Seatback from the vehicle.

1. Seatback to the vehicle.
2. Washer (30) between the seat base and the seatback
frame.
Figure 5Seat Back Catch Components
10A2-6 SEATS
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
R e tra c to r
B u c k le
A n c h o r P late
B o lt
Plug
B o lt
Plug
B o lt
C over
Figure 6Bucket Seat Belt Components

4.
5.
6.
7.
9. Buckle (34) to floor bolt (38).

10. Buckle from the floor.
Washer (30).
Catch (28) with bushing (29).
Striker (27).
Seat back trim cover (32).
NOTICE: For steps 2, 6, and 9 see N otice on

page 10A2-1 o f this section.
SEAT BELT REPLACEMENT

This procedure covers belts for all seats except high
back bucket seats.
El
Install or Connect
1. Buckle (38) to the floor.
2. Buckle to floor bolt (38).
1. Upper seat belt anchor plate cover (42).

Pry the top of the cover away from the anchor
plate.
2. Anchor plate bolt (36).
3. Anchor plate (35).
4. Plug (39) (except regular cab).
5. Retractor (33) to floor bolt (40).
6. Seat belt wire (left side only).
7. Retractor from the vehicle.
8. Plug (37).
Tighten
3.
4.
5.
6.

Plug (37).
Retractor to the vehicle.
Seat belt wire (left side only).
Retractor to floor bolt (40).
&
Tighten

Plug (39) (except regular cab).
Figure 7Bench Seat Belt Components
SEATS 10A2-7
45
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
B u c k le
R e tra c to r
A n c h o r Plate
L ow er A n c h o r
B o lt
B o lt
C over
B o lt
Plug
B o lt
F lap
F-00595
Figure 8High Back Bucket Seat Belt Components

8. Anchor plate (35) to the door pillar.
Tighten

Pivot the cover upwards, and press it into place.
HIGH BACK BUCKET SEAT

BELT REPLACEMENT
Install or Connect
Buckle to the floor.
Seat belt wire (left side only).
Buckle (43) to floor bolt (50).
Tighten

Plug (51).
Retractor to the vehicle.
Lower anchor (46) to the pillar.
Lower anchor bolt (53).

Pry the top of the cover away from the anchor
plate.
4. Retractor lower flap (54).
5. Retractor (44) to pillar bolt (47).
6. Lower anchor bolt (53).
7. Lower anchor (46).
8. Retractor from the vehicle.
9. Plug (51).
10. Buckle (43) to floor bolt (50).
11. Seat belt wire (left side only).
12. Buckle from the floor.
NOTICE: For steps 3, 7, 8 and 11see Notice

onpage 10A2-1of this section.

Retractor (44) to pillar bolt (47).
Tighten

9. Retractor lower flap.

10A2-8 SEATS
RV MODEL SUBURBAN CENTER SEAT
1.
2.
3.
4.
5.
CENTER SEATBACK
REPLACEMENT
Fold the seatback forward.
Hinge (57) to floor panel bolts (58).
Seatback (55 or 56) from the vehicle.
Seal (59).
Hinge (57) to seatback bolts (60).
Hinge (57) from the seatback (55 or 56).
|-+| Install o r Connect (Figure 9)

1. Hinge (57) to the seatback (55 or 56).
2. Hinge (57) to seatback bolts (60).

3. Seal (59).
4. Seatback (55 or 56) to the vehicle.
5. Hinge (57) to floor panel bolts (58).
CENTER SEAT BOTTOM

REPLACEMENT
1.
2.
3.
4.
Fold the seat bottom forward.

Bracket (105) to floor panel bolts (61).
Seat bottom (55 or 56) from the vehicle.
Center stop bracket bolts (103) and bracket (64).
Side stop bracket bolts (104) and brackets (63).
Install or Connect
1. Side stop bracket (63) and bolts (104).
2. Center stop bracket (64) and bolts (103).
3. Seat bottom (55 or 56) to the vehicle.
4. Bracket (105) to floor panel bolts (61).
CENTER SEAT BOTTOM

SUPPORT BRACKET
REPLACEMENT
1. Trim panel bolts (69) and the panel (68).
2. Bracket to seat bolts (67).
3. Bracket to floor panel bolts.
4. Bracket (105) from the vehicle.

1. Bracket (105) to the vehicle.
2. Bracket to floor panel bolts.
3. Bracket to seat bolts (67).
4. Trim panel (68) and bolts (69) to the seat.
SEATS 10A2-9
61.
62.
63.
64.
103.
B o lt
B ra cket
Large Seat
B o tto m
S m a ll Seat
B o tto m
B o lt
C over
B ra cket
S to p
B o lt
Figure 10Center Seat Body Mounting
CENTER SEATBACK BUMPER

AND STRIKER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.

Bumper covers (73).
Bumper (75) to seat bolts (74).
Bumpers (75).
Striker bolts (76).
Striker (77).
Spacer (78).
Plate (79).

1.
2.
3.
4.
5.
6.
7.
Plate (79).
Spacer (78) as required.
Striker (77).
Striker bolts (76).
Bumpers (75).
Bumper (75) to seat bolts (74).
Bumper covers (73).
CENTER SEAT BOTTOM

STRIKER REPLACEMENT

1. Striker (65) to the seat.
2. Striker (65) to seat bolts (66).
CENTER SEATBACK
LATCH REPLACEMENT
1. Latch bolts (83).
2. Latch from the vehicle.

1. Latch to the vehicle.
2. Latch bolts (83).
CENTER SEAT BOTTOM

LATCH REPLACEMENT
1. Latch to floor panel bolts (89).
2. Latch (88) from the vehicle.

1. Striker (65) to seat bolts (66).
2. Striker (65) from the seat.
Install or Connect
1. Latch (88) to the vehicle.
2. Latch to floor panel bolts (89).
SEATS 10A2-11
76
72.
73.
74.
75.
76.
77.
78.
79.
77
S crew
C over
B o lt
Bum per
B o lt
S trik e r
S pacer
Plate
B-07257
Figure 12Center Seatback Bumper and Striker Components
CENTER SEAT BELT

REPLACEMENT
Fold the seat bottoms forward.
Note the position of the belts.
Tighten

Guide assemblies (96) and guide bolts (97).
Retractor (92) to the vehicle.
Retractor bolts (93).
Tighten
1. Retractor flaps (94).
Retractor bolts to 50 N m (37 ft. lbs.).

6. Retractor flaps (94).
2. Retractor bolts (93).

3. Retractor (92) from the vehicle.
4. Guide assembly bolts (97) and the guides (96).
5. Buckle (95) and latch plate (99) assembly bolts (98).
6. Buckle and latch plate assemblies from the vehicle.

NOTICE: For steps 2 and 5 see
N o tice on
1. Buckle and latch plate assemblies to the vehicle.

2. Buckle and latch plate assembly bolts (98).
10A2-12 SEATS
82.
83.
84.
85.
B ra cket A s s e m b ly
B o lt
Bum per
S crew
B-07258
Figure 13Center Seatback Latch
92.
93.
94.
95.
96.
97.
98.
99.
R e tra c to r
B o lt
F lap
B u c k le
G u id e
B o lt
B o lt
L atch Plate
B-07260
Figure 15Center Seat Belt Components
SEATS 10A2-13
RV MODEL REAR SEATS

CREW CAB REAR SEATBACK
AND CATCH REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Seat back trim cover (32).

Striker (27).
Catch (28) with bushing (29).
Washer (30).
Seatback to seat base bolt (26).
Washer (30).
Seatback from the vehicle.

1. Seatback to the vehicle.
2. Washer (30) between the seat base and the seatback
frame.
4. Washer (30).
5. Catch (28) with bushing (29).
6. Striker (27).
7. Seat back trim cover (32).
CREW CAB REAR SEAT

BELT REPLACEMENT
RETRACTOR REPLACEMENT
1. Retractor to floor panel bolts (115).
2. Retractor (112).
1. Retractor (112) to the floor panel.
NOTICE: See N o tice on page
section.
10A2-1 o f this
2. Retractor to floor panel bolts (115).
Tighten
CREW CAB REAR

SEAT REPLACEMENT
1. Rear bracket (107) to floor bolts (106).
CENTER BUCKLE AND LATCH PLATE

REPLACEMENT
2. Front bracket (109) to floor bolts (110).

4. Front and rear bracket to seat bolts (108).
5. Rear bracket (107).
6. Front bracket (109).

1. Front bracket (109) and bolts (108).
2. Rear bracket (107) and bolts (108).
3. Seat to the vehicle.
4. Front bracket (109) to floor bolts (110).
5. Rear bracket (107) to floor bolts (106).
1.
2.
3.
+4"
Seat. Refer to Crew Cab Rear Seat Replacement.

Note the position of the belts.
Belt to floor panel bolts (114).
Left belt (113) and right belt (113) from the vehicle.
1. Left belt (113) and right belt (113) to the vehicle.

NOTICE: See N o tice on page
section.
2. Belt to floor panel bolts (114).
10A2-1 of this
10A2-14 SEATS
Tighten
UTILITY VEHICLE REAR

SEAT STORAGE STRUT
REPLACEMENT

3. Seat. Refer to Crew Cab Rear Seat Replacement.

SEAT REPLACEMENT
Fold the seat forward.
1. Hinge to floor bolt (116) and spring washer (117).
1.
2.
3.
Tilt the seat forward.

Strut (125) to floor bolts (126).
Strut (125) to seat bolts (127).
Strut from the vehicle.

1. Strut (125) to the vehicle.
2. Strut (125) to seat bolts (127).
3. Strut (125) to floor bolts (126).
1. Seat to the vehicle.

2. Spring washer (117) and bolt (116).
UTILITY VEHICLE REAR SEAT

COVER ROD REPLACEMENT
1. Actuator rod clip (123).
2. Actuator rod (124).

SEAT BELT REPLACEMENT
Fold the seat forward.
1. Side latch plate (128) to floor panel bolts (129).
2. Side latch plate (128) from the vehicle.
3. Rear seat cover rod.
4. Latch and support assembly from the seat. Refer to
Utility Vehicle and Suburban Latch and Support
Assembly Replacement.
1. Actuator rod (124).
5. Seat belt (130) to latch bolts (131).
2. Actuator rod clip (123).
6. Seat belts from the latch.
SEATS 10A2-15

3. Latch and support assembly to the seat. Refer to

Utility Vehicle and Suburban Latch and Support
4. Rear seat cover rod.
1. Seat belts (130) to the latch.
5. Side latch plate (128) to the vehicle.
2. Seat belts (130) to latch bolts (131).
6. Side latch plate (128) to floor panel bolts (129).
Tighten
Bolts to 50 Nm(37 ft. lbs.).
Figure 19Utility Vehicle Cover Rod
Tighten
Bolts to 50 N m(37 ft. lbs.).
Figure 20Utility Vehicle Storage Strut
10A2-16 SEATS
UTILITY VEHICLE AND

SUBURBAN SEATBACK AND
HINGE REPLACEMENT
132.
133.
134.
135.
136.
137.
138.
139.
153.
154.

1.
2.
3.
4.
5.
6.
Seatback to hinge bolts (139).

Seatback (154) from the vehicle.
Hinge (153) to seat bottom bolts (137).
Hinge from the vehicle.
Armrest to hinge bolt (136).
Armrest support (138) from the hinge.
132
A sh Tray
A rm re s t
S p rin g W a sh er
B o lt
B o lt
B o lt
S u p p o rt
B o lt
H in g e
S e atba ck
Install or Connect
1.
2.
3.
4.
5.
6.
Armrest (133) to the hinge.

Armrest to hinge bolt (136).
Hinge to the vehicle.
Hinge (153) to seat bottom bolts (137).
Seatback (154) to the vehicle.
Seatback to hinge bolts (139).
154
UTILITY VEHICLE AND

SUBURBAN LATCH AND
SUPPORT ASSEMBLY
REPLACEMENT
Fold the seat forward (Utility vehicle only).
1. The seat (Suburban only). Refer to Suburban Seat
Replacement.
2. Latch cover rod (Utility vehicle only).
3. Latch cover (Suburban only) (141).
4. Latch to seat bolts (145).
5. Latch (144) from the seat.
6. Latch cover (143) (Utility vehicle only).
137
B-07267
Install or Connect
1. Latch cover (141) to the seat (Utility vehicle only).
2. Latch (144) to the seat.
3. Latch to seat bolts (145).
Figure 22Left Seatback Hinge
SEATS 10A2-17
4. Latch cover (Suburban only).
5. Latch cover rod (Utility vehicle only).
6. The seat (Suburban only). Referr to Suburban Seat
Replacement.
SUBURBAN REAR
SEAT REPLACEMENT
REMOVAL
139
136.
137.
138.
139.
140.
1. Unlatch the seat, and pull towards the rear of the

vehicle.
2. Remove the seat from the vehicle.
*-e f
S crew
S crew
S u p p o rt
B o lt
H in g e A nd Latch
INSTALLATION
1. Place the seat in the vehicle.
2. Place the hooked retainers onto the anchor pins.
B-07268
Figure 23Right Seatback Hinge
141. C ove r
142. B o lt
141
B-09074
Figure 24Suburban Rear Seat Latch Cover
10A2-18 SEATS
4. Side buckle (148) to floor panel bolts (149).
5. Buckle (148) from the vehicle.
Install or Connect
1. Buckle (148) to the vehicle.

2. Buckle (148) to floor panel bolts (149).

3. Seat belts (151 and 152) to the seat.
4. Seat belt to latch bolts (150).
Tighten

5. Rear seat latch cover (figure 24).
Figure 25Rear Seat Latch Components

3. Latch the seat.
4. Push back and forth on the seat to be sure it is latched.
SUBURBAN REAR SEAT

BELT REPLACEMENT
1. Rear seat latch cover (figure 24).
2. Seat belts (151 and 152) to latch bolts (150).
3. Seat belts from the seat.
148.
149.
150.
151.
B u c k le
B o lt
B o lt
B u c k le
A s s e m b ly
152. L a tch Plate
B-09076
Figure 26Suburban Rear Seat Belts
SEATS 10A2-19
RV MODEL TOP STRAP BELT ANCHOR INSTALLATION

section.
5. Install the bolt (161), anchor bracket (160), anchor plate
(158), and lock nut (159) to the hole with an appropriate
sealant.
6. Tighten the nut to 31 N m (23 ft. lbs.).
Use the Child Seat only in the seating position for
which the anchor bracket has been installed, latching
the Child Seat top strap hook to the anchor bracket as
shown.
CAUTION: In the event that the Child Seat

anchorage assembly is removed, the 8 mm
(5/ie-inch) diam eter hole must be properly
resealed to prevent toxic exhaust fumes from
entering the cab.
156.
157.
158.
159.
160.
161.
W in d o w
S e ale r
A n c h o r Plate
N ut
A n c h o r B ra cket
B o lt
B-09152
Figure 27Pickup Top Strap Belt Components

All hardware discussed in this procedure should be
supplied or available from the child seat manufacturer. Be
sure the child seat position does not conflict with any ad
ditional requirem ents provided by its manufacturer, or with
any recomm endations in the Child Restraint section of the
O w ners Manual.
The child seat may be used only in a forward facing
seating location.
PICKUP AND CREW CAB MODELS

1. Place the Child Seat in the front seating position (rear
seating position on crew cab models) (figure 27).
2. Secure the vehicle lap belt over the armrests of the
Child Seat in the position which the Child Seat will be
used.
3. Select a suitable anchor bracket mounting location on
the cab back panel. The location must be:
Located near the rear window reinforcement.
The angle between the Child Seat top strap and
horizontal should not exceed 45.
As close to the center line of the Child Seat as
possible, but in no case more than 50 mm
(2-inches) towards the passenger side of the cab,
and 150 mm (6-inches) towards the drivers side
of the cab.
In a position clear of the fuel tank, fuel lines,
brake lines, exhaust systems, etc.
4. Drill an 8 mm (5/ie-inch) diameter hole through the cab
panel at the selected location.
UTILITY VEHICLE
REAR SEAT
1. Determine the location for the anchor by measuring
140 mm (51/2-inches) forward from the rear edge of the
floor pan (figure 28). Make this measurement in the
center of one of the depressed floor pan ribs. Next,
measure 1330 mm (52.25-inches) inboard of the right
quarter inner panel. Mark the position where these
measurements meet.
2. Drill an 8 mm (5/ie-inch) hole at the mark.
3. To insure proper sealing of the hole, remove any dirt or
foreign matter from around the hole on the underside
of the floor pan where the sealer is to be applied.
section.
4. Place sealer on the hole from the underside of the
vehicle and assembly the bolt (162), anchor plate (163),
washer (165), and lock nut (166) to the floor pan.
5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child
Seat only in the seating position for which the anchor
bracket has been installed.
NOTICE: In the event the Child Seat anchorage
assembly is removed, the 8 mm (s/i6 inch)
diam eter hole must be properly resealed.
SUBURBAN FRONT SEAT

This procedure applies to vehicles not equipped with a
second seat or vehicles with the second seat in the down
position.
1. Determine the location for the anchor by measuring 51
mm (2-inches) rearward from the rear edge of the kick
up molding. Make this measurement in the center of
one of the depressed floor pan ribs (figure 29).
A. Measure 360 mm (14.6-inches) inboard of the
right quarter inner panel for the right seating
position.
10A2-20 SEATS
.
/c cn"\
1 4 0 m m (5 .5 0 )
j i ; y s
162.
163.
164.
165.
166.
B o lt
A n c h o r Plate
S ealer
W a sh er
N ut
F-02685
Figure 28Utility Vehicle Second Seat Top Strap Belt Components
Figure 29Suburban Front Seat Top Strap Belt Components
SEATS 10A2-21
172.
173.
174.
175.
176.
B o lt
A n c h o r Plate
S ealer
W a sh er
N ut
(55mm)
2 . 12"
55mm (2.12")
174
175
176
B-09129
F igure 30S uburban S econd Seat T op S trap B e lt C om po n en ts

B. Measure 895 mm (35.25-inches) inboard of the
right quarter inner panel for the center seating
position.
Mark the position where the measurements
meet.
section.
vehicle and assemble the bolt (167), anchor plate (168),
NOTICE: In the event the child seat anchorage
assem bly is rem oved, the 8 mm (5/ie-in ch )
SUBURBAN SECOND SEAT

650 mm (251/2-inches) rearward from the rear edge of
the kick-up molding (figure 30). Next:
A. Measure 55 mm (2.12-inches) inboard of the right
wheelhouse for the right seating position.

right wheelhouse for the center seating position.
C. Measure 55 mm (2.12-inches) inboard of the left
wheelhouse for the left seating position.
Mark the position where the measurements for the
desired seating position meet.
2. Drill an 8 mm (5/ie-inch) hole at mark.
section.
Seat only in the second seat seating position for which
the anchor bracket has been installed.
NOTICE: In the event the child seat anchorage
assem bly is rem oved, the 8 mm (5/ie -in c h )
SUBURBAN THIRD SEAT

127 mm (5-inches) forward from the rear edge of the
floor pan. Make this measurement in the center of one
of the depressed floor pan ribs (figure 31).
10A2-22 SEATS
1,160mm (45.75")
181
177.
178.
179.
180.
181.
B o lt
A n c h o r Plate
S ealer
W a sh er
N ut
B-09029
Figure 31Suburban Third Seat Top Strap Belt Components

Next:
A. Measure 535 mm (21-inches) inboard of the right
quarter inner panel for the right seating position.
right quarter inner panel for the center seating
position.
C. Measure 1,160 (45.75-inches) inboard of the right
quarter inner panel for the left seating position.
3. To insure proper sealing of the hole, remove anydirt or
section.

Seat only in the third seat seating position for which
assem bly is rem oved, the 8 mm (s/i6 -in ch )
NOTICE: If the hole penetrates to the exterior of
the vehicle, apply a sealant between the anchor
bolt washer and the sheet m etal to prevent
carbon monoxide from entering the vehicle.
S uitable sealers in c lu d e silico n e, b u tyl or
acrylic type caulking.
In the event that the child seat anchorage
assembly is removed, all bolt holes penetrating
to the exterior of the vehicle must be resealed
to prevent exhaust fumes from entering the
vehicle.
SEATS 10A2-23
G MODEL FRONT SEAT
B-09027
Figure 32Front Bucket Seat Components
FRONT SEAT REPLACEMENT
4. Seat riser to adjuster nuts (184).

5. Seat. Refer to Seat Replacement.

1. Seat belts. Refer to Seat Belt Replacement.
2. Seat riser (183) to floor panel nuts (185), washers (186),
and reinforcements (187) from underneath the vehicle.

1. Seat (182) to floor panel nuts (185), washers (186), and
reinforcements (187) to the underside of the vehicle.
Lower the vehicle.
3. Seat belts. Refer to Seat Belt Replacement.
FRONT SEAT DISASSEMBLY

1.
2.
3.
4.
5.
Seat. Refer to Front Seat Replacement.

Seat riser to adjuster nuts (184).
Seat (182) and adjuster (190) from the riser (183).
Adjuster to seat bolts (193) and spacers (191).
Adjuster (190) from the seat (182).
FRONT SEAT BELT

REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
Anchor plate (194) to the roof side rail bolt (198).

Anchor plate (194).
Seat belt warning wire (left side only).
Retractor (195) to seat riser bolt (199).
Retractor (195) and anchor plate (194) from the vehicle.
Plug (200).
Buckle (196) to seat riser bolt (201) and washer (202).
Buckle (196) from the vehicle.
NOTICE: For steps 2, 5, and 7see Notice on

page 10A2-1of this section.
1. Buckle (196) to the vehicle.
2. Buckle (196) to seat riser washer (202) and bolt (201).
- * Install or Connect (Figures 32 and 33)

1. Adjuster (190) to the seat (182).
2. Adjuster to seat spacers (191) and bolts (193).
3. Seat (182) and adjuster (190) to the riser (183).

3. Plug (200).
4. Retractor (195) and anchor plate (194) to the vehicle.
10A2-24 SEATS
B-09028
Figure 33Bucket Seat Adjusters

5. Retractor (195) to seat riser bolt (199).
Tighten
6. Seat belt warning wire (left side only).
7. Anchor plate (194) to the roof side rail.
8 Anchor P|ate bolt (198)^
Tighten
SEATS 10A2-25
Figure 34Bucket Seat Belt Components
10A2-26 SEATS
G MODEL CENTER AND REAR SEATS
CENTER AND REAR

SEAT DISASSEMBLY
CENTER AND REAR SEAT

REPLACEMENT
REMOVAL (Figure 35)

1. Unlatch the seat, and pull towards the rear of the
vehicle.
1. Seat from the vehicle. Refer to Center and Rear Seat

Replacement.
2. Remove the seat from the vehicle.
2. Support (210) and leg assembly (209) to seat bolts (207

and 208).
3. Support assembly (210) to leg assembly (209), bolts
(206) and spring washers (205).
INSTALLATION (Figure 35)

1. Place the seat in the vehicle.
4. Support assembly (210) from the legs (209).
2. Place the hooked retainers onto the anchor pins.
3. Latch the seat.
1. Support assembly (210) to the legs (209).
4. Push back and forth on the seat to be sure it is latched.
2. Support assembly (210) to leg assembly (209), springs

washers (205) and bolts (206).
205.
206.
207.
208.
209.
210.
W a sh er
B o lt
B o lt
B o lt
Leg A s s e m b ly
S u p p o rt A s s e m b ly
210
B-09030
Figure 36Center Seat Components
SEATS 10A2-27
205.
206.
207.
208.
209.
210.
W asher
Bolt
Bolt
Bolt
Leg A ssem bly
S upport A ssem bly
B-09110
Figure 37Rear Seat Components
Tighten

3. Support (210) and leg assembly (209) to seat bolts (207
and 208).
4. Seat to the vehicle. Refer to Center and Rear Seat
Replacement.

ARMREST REPLACEMENT
1.
2.
3.
4.
Armrest bracket (217) to seat bolts (216).

Armrest to seatback bolts (213).
Armrest cover (218) (if equipped).
Arm rest bracket (217) to arm rest nuts (215) and
washers (214).
5. Armrest bracket (217) from the armrest (212).
Install or Connect
1. Armrest bracket (217) to the armrest (212).

2. Armrest bracket (217) to armrest washers (214) and
nuts (215).
3. Armrest cover (218) (if equipped).
4. Armrest to seatback bolts (213).
5. Armrest bracket (217) to seat bolts (216).

BELT REPLACEMENT
42)
1. Retractor to support assembly bolts (221).
2. Retractor (220) from the seat.
3. Buckle (219) and latch plate (225) (if equipped) to
support assembly bolts (222).
4. Buckle (219) and latch plate (225) (if equipped) from
the seat.

1. Buckle (219) and latch plate (225) (if equipped) to the
seat.
2. Buckle (219) and latch plate (225) (if equipped) bolts
(222).
The shoulder of the bolt must bottom on the weld
nut.

3. Retractor (220) to the seat.
4. Retractor to support assembly bolts (221).
Tighten
10A2-28 SEATS
211.
212.
213.
214.
215.
216.
217.
212
A sh Tray
A rm R est
B o lt
W a sh er
N ut
B o lt
B-09108
Figure 39Rear Seat Armrest
211.
212.
213.
214.
215.
216.
217.
218.
A sh Tray
A rm R est
B o lt
W a sh e r
N ut
B o lt
C over
B-08586
Figure 38Center Seat Armrest
SEATS 10A2-29
219.
220.
221.
222.
B u c k le
R e tra c to r
B o lt
B o lt
B-09134
Figure 40Center Seat Belt Components
219.
220.
221.
222.
225.
B u c k le
R e tra c to r
B o lt
B o lt
L atch Plate
B-09132
Figure 41Rear Seat Belt Components
10A2-30 SEATS
S crew
C over
B-09106
Figure 42Seat Leg Cover
G MODEL TOP STRAP BELT ANCHOR INSTALLATION

All hardware discussed in this procedure should be
supplied or available from the child seat manufacturer. Be
sure the child seat position does not conflict with any ad
ditional requirements provided by its manufacturer, or with
any recomm endations in the Child Restraint section of the
Ow ners manual.
The child seat may be used only in a forward facing
seating location.
Installation of top strap belts is not recommended in the
front passenger seat of G Vans. The second seat offset
which allows passenger entry does not position a second
seat lap belt within the recommended zone for attach
ment to the top strap hook. Also, a floor anchorage is
impractical since the top strap length is insufficient to di
rectly connect the restraint to the floor with high back
bucket seats.
VEHICLES WITH A
125-INCH WHEELBASE
SECOND SEAT LEFT SEATING POSITION
This procedure is for vehicles not having a third seat.
mm (3-inches) rearward from the front edge of the left
wheelhouse. Measure 60 mm (2 3/s-inches) inboard
from the left wheelhouse. Mark the position on top of
the rib where these measurements meet (figure 43).
of the floor pan where sealer is to be applied.
section.
vehicle and assemble the bolt (227), anchor bracket
226.
227.
228.
229.
230.
231.
232.
233.
R ig h t W h e e lh o u s e
B o lt
A n c h o r B ra cket
S e ale r
S p a c e r W a sh ers
A n c h o r Plate
L ock N u t
F ro n t E dge O f The L e ft W h e e lh o u s e
B-09127
Figure 43Second Seat Top Strap Components

Left Position
(228), two 35 mm (13/s-inch) outside diameter spacer
washers (230), anchor plate (231) and lock nut (232) to
the floor pan.
SEATS 10A2-31
233.
234.
235.
236.
237.
238.
239.
240.
B o lt
A n c h o r B ra cke t
S e ale r
A n c h o r Plate
L ock N ut
F ro n t Edge O f The R ig h t W h e e lh o u s e
S p a ce r W ashers
A. R ig h t S e a tin g P o s itio n
B. C e n te r S e a tin g P o s itio n
B-09128
Figure 44Second Seat Top Strap ComponentsCenter and Right Position

assem bly is rem oved, the 8 mm (s/i6 -in ch )
SECOND SEATCENTER OR RIGHT

SEATING POSITIONS
This procedure is for vehicles not having a third seat.
mm ( 13/8-inch) rearward from the front edge of the left
wheelhouse (figure 44). Next:
A. Measure 580 mm (227/a-inches) inboard from the
right wheelhouse for the center seating position.
B. Measure 395 mm (151/2-inches) inboard of the
right wheelhouse for the right seating position.
desired seating positions meet.
section.
(237), two 35 mm (13/e-inch) outside diameter spacer
washers (240), anchor plate (237) and lock nut (238) to
the floor pan.
assem bly is rem oved, the 8 mm (5/ie -in ch )
THIRD SEAT
It is recommended that only the left seating position be
used for the third seat.
mm (3-inches) rearward from the left wheelhouse.
M easure 10 mm ( 3/s-inch) inboard from the left
w h e e lh o u s e . M ark th e p o s itio n w he re th o s e
measurements meet (figure 45).
section.
(242), anchor plate (244) and lock nut (245) to the floor
pan.
VEHICLES WITH A
110-INCH WHEELBASE
SECOND SEAT
This procedure is for vehicles without a third seat
(figures 46 and 47).
1. Determine the location of the anchor by:
A. Measuring 457 mm (18-inches) rearward from
the front edge of the left wheelhouse. Measure
50 mm (2-inches) inboard of the left wheelhouse
for the left seating position.
B. Measuring 546 mm (211/2-inches) rearward from
the front edge of the left wheelhouse. Make this
m easurem ent in the center of one of the
10A2-32 SEATS
241.
242.
243.
244.
245.
246.
247.
B o lt
A n c h o r B ra cke t
S e ale r
A n c h o r Plate
N ut
L e ft W h e e lh o u s e
Figure 45Third Seat Top Strap ComponentsLeft Position

depressed floor pan ribs. Next, measure 580 mm
(2 2 7/a-inches) inboard of the left wheelhouse for
the center seating position.
C. Measure 546 mm (211/2-inches) rearward from
the front edge of the right wheelhouse. Next,
measure 395 mm (151/2-inches) inboard from the
right wheelhouse for the right seating position.
desired seatings positions meet.

NOTICE: See N otice on page 10A2-1 o f this
section.
(249), anchor plate (251) and lock nut (252) to the floor
pan.
Seat only in the second seat seating position for which
SECOND SEAT VEHICLES EQUIPPED WITH

A THIRD SEAT
Use the Child Seat as directed in the usage instructions
furnished with the Child Seat, in any second seating
position. Latch the Child Seat top strap hook to the third
seat lap belt tongue located most directly behind the Child
Seat.
THIRD SEAT
253 - + / 250
251
248.
249.
250.
251.
252.
253.
7 :50mm (2 ")
B o lt
Anchor
S ealer
A n c h o r Plate
L ock N ut
F ro n t Edge O f T he L e ft W h e e lh o u s e
B-09131
Figure 46Second Seat Top Strap Components

Left Position
The Child Seat is not recommended for use in the third

seat of a 110-inch wheelbase model.
SEATS 10A2-33
248.
249.
250.
251.
252.
253.
A.
B.
Bolt
A n cho r Bracket
Sealer
A nch or Plate
Lock Nut
Front Edge Of The Left
R ight Seating P osition
C enter Seating P osition
B-09037
Figure 47Second Seat Top Strap ComponentsCenter and Right Position
10A2-34 SEATS
SPECIFICATIONS
ITEM
RV Models
All Seat Belt Fasteners Except Top S tra p .................................................................................
N m
TORQUE
FT. LBS.
50
37
G Models
Front Seat Belt Fasteners..................................................................................................................
Center And Rear Seat Belt Fasteners Except Top S tra p .......................................................
60
50
44
37
Top Strap Fasteners

All M o d e ls .............................................................................................................................................
31
23
GLASS 10A3-1
SECTION 10A3
GLASS
NOTICE: If a glass is cracked but still intact, it should be crisscrossed with masking tape to reduce the risk of
damage to the vehicle. If a crack extends to the edge o f the glass, mark the cab with a piece of chalk at the point
where the crack meets the cab.
CONTENTS
SUBJECT
PAGE
RV M o d e ls .................................................................................................................................................................10A3- 1
Windshield Replacement...................................................................................................................................... 10A3- 1
Stationary Glass Replacement............................................................................................................................10A3- 3
G M o d e ls ...................................................................................................................................................................10A3- 6
Windshield Replacement...................................................................................................................................... 10A3- 6
Stationary Glass Replacement............................................................................................................................10A3-10
All Models.................................................................................................................................................................. 10A3-11
Glass P o lis h in g .................................................................................................................................................... 10A3-11
Special T o o ls.............................................................................................................................................................10A3-12
RV MODELS
WINDSHIELD REPLACEMENT
When replacing a cracked windshield, it is important
that the cause of the crack be determ ined and the
condition corrected, before a new glass is installed. The
cause of the crack may be an obstruction or high spot
somewhere around the flange of the opening; cracking
may not occur until pressure from the high spot or
obstruction becomes p articularly high due to winds,
extremes of temperature, or rough terrain. Suggestions of
what to look for are described later in this section under
Inspection .
If a crack extends to the edge of the glass, mark the
point where the crack meets the weatherstrip. (Use a
piece of chalk and mark the point on the cab, next to the
weatherstrip.) Later, when examining the flange of the
opening for a cause of the crack start at the point marked.
The higher the temperature of the work area, the more
pliable the weatherstrip will be. The more pliable the
weatherstrip, the more easily the w indshield can be
removed.

handling glass to avoid the risk of injury.
Tool Required:
J-24402-A, Glass Sealant Removal Knife
Place protective coverings around the glass removal
area.
1. Reveal molding cap.
2. Reveal molding.
2 . C ap
3. G la ss
"T
4. W in d s h ie ld Reveal M o ld in g
B-09049
Figure 1Windshield Components

From inside the cab, apply a firm controlled
pressure to the edge of the glass while forcing
the weatherstrip from the flange with a flat-blade
tool.
section.
3. Windshield glass.
With the aid of a helper from outside the vehicle,
remove windshield from opening.
4. Excess urethane and remaining weatherstrip from the
pinchweld flange.
10A3-2 GLASS
4.
5.
6.
7.
8.
Figure 2Forcing the Weatherstrip Over the Flange

IQ* Clean
Pinchweld with a dry cloth.
INSPECTION
An inspection of the flange of the windshield opening,
the weatherstrip, and the glass may reveal the cause of a
broken windshield. This can help prevent future breakage.
If th e re is no a p p a re n t c a u s e o f b re a k a g e , th e
weatherstrip should be removed from the flange of the
opening and the flange inspected. Look for high weld or
solder spots, hardened spot weld sealer, or any other
o bstruction or irre g u la rity in the flange. C heck the
weatherstrip for irregularities or obstructions in it.
Check a windshield that is to be installed to make sure
it does not have any chipped edges. Chipped edges can
be ground off, restoring a smooth edge to the glass, and
m in im iz in g c o n c e n tra tio n s of p re ssu re th a t ca use
breakage. Remove no more than necessary, in an effort to
maintain the original shape of the glass and the proper
clearance between it and the flange of the opening. See
G lass-To-O pening C lea ra nce C h e c k later in th is
section.
GLASS-TO-OPENING CLEARANCE CHECK

Before installing a windshield, the clearance between
the edge of the glass and the flange of the opening
should be checked. On RV Models the glass and flange
overlap by 5 mm (0.2-inch). If the windshield is too big,
rework the metal flange or grind off the edge of the glass.
If the glass is to be ground off, place a strip of tape on the
glass and use the edge of the tape as a guide.
If there is too much clearance between the glass and
the flange of the opening, the flange can be built up.
Braze a piece of 3 mm (Ve-inch) diameter wire to the edge
of the flange. Usually, building up one side and half way
around one corner will be enough. Taper off the ends of
the wire to avoid an abrupt change in contour which could
result, later, in a broken windshield.
Rubber cleaner.
Rubber primer.
Pinchweld primer.
Blackout primer.
Filler strip (for use on windshield installations for
v e h ic le s e q u ip pe d w ith e m b edded w in d s h ie ld
antenna).
9. Primer applicators.
Other materials are required for windshield installation
which are not included in the service kit. These include:
1. GM Rubber lubricant No. 1051717.
2. Alcohol for cleaning the edge of the glass.
3. Adhesive dispensing gun J-24811 or
4. A standard household cartridge type gun reworked as
follows:
a. Widen the end slot to fit the diameter of the
dispensing nozzle of the adhesive tube.
b. Reduce the diameter of the plunger disc so that
the disc will enter the large end of the adhesive
tube.
5. Commercial type razor knife (for cutting along the edge
of the glass).
6 . Weatherstrip Tool J-2189-02.
W indshield installation requires a num ber of timed
steps because of the cure tim es involved with the primers,
solvents, and adhesives used in this procedure. This
tim ing is important and must be followed.

Tools Required:
J-24811 Adhesive Dispensing Gun
J-2189-02 Weatherstrip Tool
1. Pinchweld primer.
Primer must be thoroughly stirred and agitated.
Allow to cure for 30 minutes.
2. R u b b e r c le a n e r to both c h a n n e ls of ru b b e r
weatherstrip.
Wait 5 minutes before wiping the channels with a
clean dry cloth.
3. Rubber primer to both channels of the weatherstrip.
Wait 30 minutes for curing.
XJJK Clean
4.
5.
SERVICE KIT
To rep la ce a u re th a n e a d h e re d w in d s h ie ld , GM
adhesive service kit No. 9636067 contains some the
m aterials needed, and must be used to insure the original
integrity of the w indshield design. Materials in the kit
include:
1. One tube of adhesive material.
2 . One dispensing nozzle.
3. Steel music wire.
6.
7.
8.
9.
Inner surface of glass with a clean alcohol

dampened cloth. Allow the glass to air dry.
Blackout primer to the inside face of the glass.
Start 10 mm (.40-inch) from the edge and work
the primer outward to the edge.
Allow the primer to dry.
Urethane adhesive bead with a diameter of 6 mm
(.25-inch) to the center of the pinchweld flange around
the entire windshield opening.
Glass must be installed within 20 minutes of
performing this step.
Spray a mist of water to the urethane bead,
wetting it fully.
Rubber weatherstrip to the pinchweld flange.
Urethane adhesive bead with a 4.5 mm (.18-inch)
diameter to the rubber weatherstrip glass channel
(figure 3).
Glass to the window opening.
Rubber lubricant to the lockstrip channel.
Glass must be seated before the lubricant is
applied.
GLASS 10A3-3
5.
6.
7.
8.
9.
10.
11.
P rim e r L o ca tio n
R u b b e r C lea ne r A n d P rim e r L o c a tio n
C le a n e r L o ca tio n
B la c k o u t P rim e r L o c a tio n
10 m m (0.40-inch)
U re th an e L o ca tio n
R u b b e r L u b ric a n t L o c a tio n
Figure 3Primer and Adhesive Application Locations

10. Reveal molding to the weatherstrip using J-2189-02
(figure 4).
STATIONARY GLASS
REPLACEMENT
11. Reveal molding cap at the joint.

1. Reveal molding.
Push the clip to one side to free the ends.
this section.
2. Window glass.
Insert a putty knife between the glass and the
weatherstrip and run the knife around the entire
edge of the window.
this section.
With a helper standing outside the vehicle, push
the glass from the weatherstrip from inside the
cab while the helper removes the glass.
install or Connect (Figures 5 through 9)

Tool Required:
J-2189-02 Weatherstrip Tool
10A3-4 GLASS

handling glass to avoid risk of injury.
1. Sealing tape on the outside upper corners of the
opening, 120 mm (Ve-inch) wide.
2. Weatherstrip at the center of the bottom edge of the
opening and work around the entire opening of the
flange.
Brush the weatherstrip with soapy water.
Inspect
Glass for cracks or chips on the edge. If the
glass is chipped, it should be ground smooth.
3. Glass in place on the weatherstrip.
Insert the hook end of tool J-2189-02 between the
weatherstrip and the edge of the glass.
Pull the tool around the glass to slip the edge of
the glass into the groove of the weatherstrip.
4. Reveal molding.
17. S lid in g B a ck W in d o w A s s e m b ly
B-09084
Figure 6Sliding Back Window Components
GLASS 10A3-5
Thread the end of the molding through the

handle of tool J-2189-02.
Push the end of the molding into the groove of
the weatherstrip at the center of the bottom edge
(figure 4).
5. Retaining clip over one end of the molding.

Butt the ends of the molding together and secure
them with the clip.
6 . Ends of the molding, with the clip in place, into the
groove of the weatherstrip.
Move the tool around the window while feeding

the molding. Use a hitching motion to avoid
stretching the molding.
Cut any excess molding leaving the ends to
overlap by 25 mm (1-inch).
22.
23.
24.
25.
S lid in g W in d o w A s s e m b ly
W e a th e rs trip
Reveal M o ld in g
C ap
B-09089
Figure 8Sliding Body Side Window Components
10A3-6 GLASS
26.
27.
28.
29.
G la ss
Reveal M o ld in g
W e a th e rs trip
C ap
B-09091
Figure 9Suburban Rear Stationary Window Components
G MODELS
WINDSHIELD REPLACEMENT
When replacing a cracked windshield, it is important
that the cause of the crack be determ ined and the
condition corrected, before a new glass is installed. The
cause of the crack may be an obstruction or high spot
somewhere around the flange of the opening; cracking
may not occur until pressure from the high spot or
obstruction becomes p articularly high due to winds,
extremes of temperature, or rough terrain. Suggestions of
what to look for are described later in this section under
Inspection .
If a crack extends to the edge of the glass, mark the
point where the crack meets the weatherstrip. (Use a
piece of chalk and mark the point on the cab, next to the
weatherstrip.) Later, when examining the flange of the
opening for a cause of the crack start at the point marked.
The higher the temperature of the work area, the more
pliable the weatherstrip will be. The more pliable the
weatherstrip, the more easily the w indshield can be
removed.
NOTICE: When cleaning windshield glass, avoid
contacting the edge o f the plastic laminate
material (on the edge o f the glass) with volatile
cleaner. Contact may cause discoloration and
deterioration o f the plastic laminate by wicking
action. Do not use a petroleum based solvent
such as kerosene or gasoline. The presence of
oil will prevent adhesion o f new material.

1.
2.
3.
4.
5.
Tool Required:
J-24402-A, Glass Sealant Removal Knife
Place protective coverings around the glass removal
area.
Windshield wiper arms.
Interior garnish moldings.
Reveal molding cap.
Reveal molding.
Interior support molding.

this section.
6 . Windshield from the flange.
Use J-24709-1 or J-24402-A to cut the glass from

the urethane adhesive. Keep the cutting edge of
the knife against the glass, and cut the sealant
from the windshield.
W ith the aid of an a ssistan t, remove the
windshield.
Two methods of glass replacement may be used. The
first of these methods is called the short method. This
method can be used when the original adhesive is left on
the window opening pinchweld flange after the glass has
been removed. The old adhesive serves as a base for the
new glass.
The second method, is the extended method. This is
used when the original adhesive cannot be used as a
base for the new glass. The original adhesive is removed
and replace with new adhesive. When repair to the sheet
m etal or w indow opening is required, the extended
method must be used.
INSPECTION
An inspection of the flange of the windshield opening,
the weatherstrip, and the glass may reveal the cause of a
broken windshield. This can help prevent future breakage.
If th e re is no a p p a re n t c a u s e o f b re a k a g e , th e
GLASS 10A3-7
G la s s
C ap
Reveal M o ld in g
S p a c e r B lo c k
S u p p o rt M o ld in g
B-09092
Figure 10Windshield Components

weatherstrip should be removed from the flange of the
opening and the flange inspected. Look for high weld or
solder spots, hardened spot weld sealer, or any other
o bstructio n or irre gu la rity in the flange. C heck the
weatherstrip for irregularities or obstructions in it.
Check a windshield that is to be installed to make sure
it does not have any chipped edges. Chipped edges can
be ground off, restoring a smooth edge to the glass, and
m in im iz in g c o n c e n tra tio n s o f p re ssu re th a t ca use
breakage. Remove no more than necessary, in an effort to
maintain the original shape of the glass and the proper
clearance between it and the flange of the opening.
8 . Filler strip (for use on windshield installations for
v e h ic le s e q u ip p e d w ith em bedded w in d s h ie ld
antenna).
9. Primer applicators.
Other m aterials are required for windshield installation
which are not included in the service kit. These include:
1. GM Rubber lubricant No. 1051717.
2. Alcohol for cleaning the edge of the glass.
3. Adhesive dispensing gun J-24811 or
4. A standard household cartridge type gun reworked as
follows:
SERVICE KIT (Figures 12 through 16)

To re p la ce a u re tha n e a d h e re d w in d s h ie ld , GM
adhesive service kit No. 9636067 contains some of the
m aterials needed, and must be used to insure the original
integrity of the windshield design. Materials in the kit
include:
1. One tube of adhesive material.
2. One dispensing nozzle.
3. Steel music wire.
4. Rubber cleaner.
5. Rubber primer.
6 . Pinchweld primer.
7. Blackout primer.
Figure 11Cutting the Glass from the Adhesive
Figure 12Primer Applications Locations
10A3-8 GLASS
Figure 14Urethane Application

a. Widen the end slot to fit the diameter of the
dispensing nozzle of the adhesive tube.
b. Reduce the diameter of the plunger disc so that
the disc will enter the large end of the adhesive
tube.
5. Commercial type razor knife (for cutting along the edge
of the glass).
6 . Weatherstrip Tool J-2189-02.
W indshield installation requires a num ber of timed
steps because of the cure tim es involved with the primers,
solvents, and adhesives used in this procedure. This
tim ing is important and must be followed.
SHORT METHOD
Clean
1. Loose material from the glass frame opening.
2. Edge of the glass with alcohol or equivalent.

1. Support molding onto the pinchweld flange from inside
the vehicle.
Locate the joint of the molding at the bottom
center of the molding.
2. Clear glass primer to the inner edge of the windshield
from the edge of the glass inward 10 mm (.40-inch),
and around the entire perimeter of the glass.
Allow 30 minutes to cure.
3. Blackout primer to the glass in the same area as the
clear primer.
Allow to dry to the touch.
4. Windshield.
Place two rubber blocks onto the base of the
pinchweld flange. Place the blocks in line with
the last screw on either side of the cowl grille
cover.
With the aid of a helper, left the glass into the
opening. Center the glass in the opening, on top
of the support molding.
Check the fit of the reveal molding. If necessary,
remove the glass and cut away additional
urethane to give the proper windshield height.
Place the glass in the window opening.
GLASS 10A3-9
34
32
34. S u p p o rt M o ld in g
36. U re th an e A d h e s iv e
30
B-09105
Figure 16Windshield Support M o ld in g Short Method

C ut th e tip of the a d h e s iv e c a rtrid g e
approximately 5 mm (3/ie-inch) from the end of
the tip.
Apply the adhesive first in and around the spacer
blocks. Apply a smooth continuous bead of
adhesive into the gap between the glass edge
and the sheet metal. Use a flat-bladed tool to
paddle the material into position if necessary. Be
sure that the adhesive contacts the entire edge
of the glass, and extends to fill the gap between
the glass and the primed sheet metal (extended
method) or solidified urethane base (short
method).
Spray a mist of water onto the urethane. Water
will assist int he curing process. Dry the area
where the reveal molding will contact the body or
glass.
31
5. New reveal moldings.

Remove the protective tape covering the butyl
adhesive on the underside of the molding.
Push the molding caps onto each end of one of
the reveal moldings.
Press the lip of the molding into the urethane
adhesive while holding it against the edge of the
windshield. Take care to seat the molding in the
corners. The lip must fully contact the adhesive
and the gap must be entirely covered by the
crown of the molding.
30.
31.
32.
34.
36.
G la ss
C ap
Reveal M o ld in g
S u p p o rt M o ld in g
U rethane A d h e sive
Slide the m olding caps onto the adjacent

moldings.
Use tape to hold the molding in position until the
adhesive cures.
B-09104
6 . Wiper arms.
7. Interior garnish moldings.
Figure 15Reveal Molding
Allow the vehicle to sit for sixe hours before

driving.
10A3-10 GLASS
EXTENDED METHOD
STATIONARY GLASS
REPLACEMENT
Clean
The old adhesive from the pinchweld flange using a
sharp scraper or chisel.

|-+-| Install or Connect (Figure 12)
1. Rivets (if equipped) using a 5 mm (3/ie-inch) drill bit.

Pinchweld primer to the pinchweld area.
Do not allow primer to touch exposed paint.
Allow 30 minutes to dry.
Follow the steps as listed under Short Method in this
section for the rest of this procedure.

this section.
2. Window glass and weatherstrip.
Run a putty knife around the edge of the window,
between the weatherstrip and the cab panels
(inside and outside the cab).
40. G la ss
40
B-09118
Figure 18Body Side Rear Window
GLASS 10A3-11
42. R ivet
B-09119
Figure 19Body Side Rear Window Riveted

Have a helper stand outside the cab next to the
window.
Use a putty knife, or other blunt tool, to force the
edge of the weatherstrip off the flange of the
opening inside the cab, while pushing out on the
glass.
C ontinue around the window, fo rcin g the
weatherstrip off the flange, until the glass and
weatherstrip are free of the opening.
Have the h e lp e r rem ove th e g la s s and
weatherstrip from the outside of the vehicle.
L*
Inspect
Flange.
Weatherstrip.
New glass.

To ease installation, the weatherstrip can be heated
with a non-flame source. Do not heat above 52C
(125F), or for more than than 11/2 hours.
1. Weatherstrip around the edge of the replacement

glass.
Place a length of cord about 6 mm (1/4-inch) thick
in the groove of the weatherstrip where the
flange of the opening will fit.
Overlap the ends of the cord about 152 mm (6
inches) and locate at the bottom of the window.
Brush a soapy solution of water around the
outside edge of the cab opening.
2. Glass and weatherstrip to flange.
Have a helper hold the glass and weatherstrip
(with the cord around it) up to the window
opening from the outside of the cab; with the
ends of the cord placed through the opening and
hang loosely inside the cab.
While the helper holds the glass firmly in place,
pull one end of the cord, forcing the lip of the
weatherstrip up and over the flange.
Pull the cord out from around the weatherstrip.
3. Rivets (if equipped) to the weatherstrip and the side
panel with a rivet installing gun.
ALL MODELS
GLASS POLISHING
MINOR SCRATCH AND ABRASION REMOVAL
M inor scratches and abrasions can be removed or
reduced by follow ing the procedure outlined below.
P re c a u tio n s m u st be ta k e n , how ever, to p re v e n t
distortions of vision; double vision may result if an attempt
is made to remove deep scratches. Deep scratches
should not be removed from an area in the drivers line of
vision; in such cases, the glass should be replaced.
The procedure that follows was developed using a
cerium oxide compound. Follow m anufacturers directions
if other materials are used.
Recommended Equipment
1. A low speed (600-1300 rpm) rotary polisher.
2. A wool, felt, rotary polishing pad 76 mm (three-inches)

in diameter and 51 mm (two-inches) thick.
3. Powdered cerium oxide mixed with water. This is the
abrasive compound.
4. A w ide m outh c o n ta in e r to hold the a b rasive
compound.
Polishing Procedure (Figure 20)

1. Mix at least 44 ml (1.5 oz.) of cerium oxide with enough
water to obtain a creamy consistency. (If the mixture is
too thick it will cake on the felt pad more quickly. If it is
too runny, more polishing time will be needed.)
2. Draw a circle around the scratches on the opposite
side of the glass with a marking crayon, or equivalent.
3. Draw a line directly behind the scratch(es) to serve as
a guide for locating the scratch while polishing.
4. Cover the surrounding area with masking paper to
catch the drippings or spattered polish.
10A3-12 GLASS
5. Dip the felt pad attached to the polisher into the
mixture. Do not submerge the pad or allow the pad to
stay in the mixture as it may loosen the bond between
the pad and the metal plate.
NOTICE: Never hold the tool in one spot or
operate the tool on the glass any longer than 30
to 45 seconds. If the glass becomes hot to
touch, let it air cool before proceding further.
Cooling with c o ld w ater may crack heated
glass. Avoid excessive pressure. It may cause
overheating of the glass.
6. Polish the scratched area, but note the following:
a. Agitate the m ixture as often as needed to
m a in ta in th e cre a m y c o n s is te n c y o f the
compound.
b. Use moderate but steady pressure.
c. Hold the pad flat against the glass.
d. Use a feathering-out motion.
e. Dip the pad into the mixture every 15 seconds to
ensure that the wheel and the glass are always
wet during the polishing operation. (A dry pad
causes excessive heat to develop.)
f. Keep the pad free of dirt and other foreign
substances.
7. After removing the scratch, wipe the area clean of any
polish.
8. Clean the polishing pad.
SPECIAL TOOLS
J-24811
3.
J-2189-02
1. A d h e s iv e D is p e n s in g G un
2. W e a th e rs trip Tool
3. S e a la n t R em over
F-02461
INTERIOR TRIM 10A4-1
SECTION 10A4
INTERIOR TRIM
CONTENTS
SUBJECT
PAGE
RV Model Interior T rim .................................................................................................................................... 10A4- 1

Front Trim Replacement.............................................................................................................................. 10A4- 1
Pick Up Models................................................................................................................................................10A4- 3
Carpet Replacement.................................................................................................................................... 10A4- 3
Headliner And Trim Replacement...................................................... .....................................................10A4- 3
Bonus Cab M odels..........................................................................................................................................10A4- 5
Headliner And Trim Replacement...............................................................................................................10A4- 6
Utility Vehicle Models...................................................................................................................................... 10A4- 8
Headliner And Trim Replacement...............................................................................................................10A4- 8
Front Floor Compartment Replacement..................................................................................................... 10A4- 8
Suburban Models..............................................................................................................................................10A4-13
Carpet Replacement.................................................................................................................................... 10A4-13
Headliner And Trim Replacement...............................................................................................................10A4-13
Roof Rear Header Trim Panel Replacement............................................................................................... 10A4-14
G Model Interior T rim ...................................................................................................................................... 10A4-18
Carpet Replacement.................................................................................................................................... 10A4-18
Headliner Replacement................................................................................................................................ 10A4-18
Interior Trim Replacement.......................................................................................................................... 10A4-19
Engine Cover Replacement.......................................................................................................................... 10A4-21
RV MODEL INTERIOR TRIM

The following procedure covers the trim located at the
front of the cab, and applies to all RV models.
FRONT TRIM REPLACEMENT

++
1.

Sill plate screws (1).
2 . Sill plate (2).
3.
4.
5.
6.
7.
Kick panel screws (3).

Kick panel (4).
Instrument panel outer filler screws (5).
Instrument panel outer filler (6).
Upper garnish molding screws (7).
8 . Upper garnish molding (8).
9. Windshield side garnish molding screws (9).
10. Windshield side garnish molding (10).

Windshield side garnish molding (10).
Windshield side garnish molding screws (9).
Upper garnish molding (8).
Upper garnish molding screws (7).
Instrument panel outer filler (6).
Instrument panel outer filler screws (5).
7.
8.
9.
10.
Kick panel (4).

Kick panel screws (3).
Sill plate (2).
Sill plate screws (1).
10A4-2 INTERIOR TRIM
Figure 3Instrument Panel Outer Filler
Figure 4Sill Plate
PICK UP MODEL
HEADLINER AND TRIM

REPLACEMENT
CARPET REPLACEMENT
++
1. Seats and seat belts. Refer to SEATS (SEC. 10A2).

2. Kick panel.
3. Front door scuff plate (12).
4. Rear panel nails (13).
Pull the nails from the panel.
5. Rear panel (14).
6. Dash panel retainers (15).
7. Carpet (16) from the vehicle.
-<- Install or Connect (Figures 5 through 8)

1. Carpet (16) to the vehicle.
2. Dash panel retainers (15).
3. Rear panel (14).
4. New rear panel nails (13).
Push the nails through the panel and into the
body panels.
6. Kick panel.
7. Seats and seat belts. Refer to SEATS (10A2).

1.
2.
3.
4.
5.
6.
7.
8.
9.
Windshield upper garnish molding screws (23).

Windshield upper garnish molding (17).
Side window garnish molding screws (21).
Side window garnish molding (22).
Windshield garnish molding screws.
Windshield garnish molding (24).
Back window garnish molding screws.
Back window garnish molding (25).
Headliner (20).

1.
2.
3.
4.
5.
6.
7.
8.
9.
Headliner (20).
Back window garnish molding (25).
Back window garnish molding screws.
Windshield garnish molding (24).
Windshield garnish molding screws.
Side window garnish molding (22).
Side window garnish molding screws (21).
Windshield upper garnish molding (17).
Windshield upper garnish molding screws (23).
Figure 7Carpet Retainers
17.
18.
19.
20.
21.
22.
23.
24.
W in d s h ie ld U pper G a rn ish M o ld in g
S cre w
B a ck W in d o w U p p e r G a rn ish M o ld in g
H e a d lin e r
S crew
S id e W in d o w G a rn ish M o ld in g
S crew
W in d s h ie ld G a rn ish
M o ld in g
25. B ack W in d o w G a rn ish
M o ld in g
B-09067
Figure 9Headliner and Interior Trim
BONUS CAB MODELS

CARPET REPLACEMENT
-- Install or Connect (Figures 10 through 12)

1. Carpet (29) to the vehicle.
++
1. Seats and seat belts. Refer to SEATS (Sec. 10A1).
2. Carpet to floor panel bolts (28) (if equipped).

3. Lock pillar garnish molding (42) and the screws (41).
2. Kick panel.
3. Front and rear door scuff plates (27).
4. Rear panel nails (figure 6).
Pull the nails from ther panel.
5. Rear panel (figure 6).
6. Dash panel retainers (figure 7).
4. Dash panel retainers (figure 7).

5. Rear panel (figure 6).
6. Rear panel nails (figure 6).
Push the nails through the panel and into the
body panels.
7. Lock pillar garnish molding screws (41) and the

molding (42).
7. Front and rear door scuff plates (27).
8. Carpet to floor panel bolts (28) (if equipped).
8. Kick panel.
9. Carpet (29) from the vehicle.
Figure 10Front Door Sili Plate
HEADLINER AND TRIM

REPLACEMENT
+- Remove or Disconnect (Figures 13 and 14)
1. Windshield upper garnish molding screws (39) and the
molding (31).
2. Side window garnish molding screws (40) and the
molding (38).
3. Windshield garnish molding screws and the molding
(30).
4. Back window garnish molding screws and the molding
(35).
5. Lock pillar garnish molding screws and the molding.
6. Sunshade screws (44) and sunshade (43).
7. Headliner (32) from the vehicle.

1.
2.
3.
4.
5.
6.
7.
Figure 11Lock Pillar Garnish Molding
Headliner (32) to the vehicle.

Sunshade (43) and screws (44).
Lock pillar garnish molding and screws.
Back window garnish molding (35) and screws.
Windshield garnish molding (30) and screws.
Side window garnish molding (38) and screws (40).
Windshield upper garnish molding (31) and screws
(39).
B-09156
Figure 12Carpet
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
W in d s h ie ld G a rn ish M o ld in g
W in d s h ie ld U pp er G a rn ish M o ld in g
H e a d lin e r
S crew
B a ck W in d o w U p p e r G a rn ish M o ld in g
B a ck W in d o w G a rn ish M o ld in g
S crew
Cap
S id e H ea de r M o ld in g
S crew
S crew
B-09135
UTILITY VEHICLE MODELS

CARPET REPLACEMENT
++

Seats and seat belts. Refer to SEATS (SEC. 10A2).
Kick panel.
Front door scuff plate.
Side trim carpet panel screws (45) and the panel (46).
Side trim panel screws (47) and the panel (48).
Floor panel trim plate screws (49) and the trim plate
(50).
Rear scuff plate screws (51) and the plate (52).
Dash panel retainers (figure 7).
Carpet (53) from the vehicle.
4. Roof rear header molding screws (60) and the molding

(53).
5. Lock pillar garnish molding screws and the molding
(61).
6. Sunshade screws and sunshade (figure 14).

1.
2.
3.
4.
5.
6.
7.

Carpet (53) to the vehicle.
Rear scuff plate (52) and screws (51).
Floor panel trim plate (50) and screws (49).
Side trim panel (48) and screws (47).
Side trim carpet panel (46) and screws (45).
Front door scuff plate.
Kick panel.
Seats and seat belts. Refer to SEATS (Sec. 10A2).
HEADLINER AND TRIM

REPLACEMENT
molding (55).
2. Side window garnish molding screws (58) and the
molding (59).
(57).
Headliner (54) to the vehicle.

Sunshade and screws (figure 14).
Lock pillar garnish molding(61) and screws.
Roof rear header molding (53) and screws (60).
Windshield garnish molding (57) and screws.
Side window garnish molding (59) and screws (58).
Windshield upper garnish molding (55) and screws
(56).
FRONT FLOOR COMPARTMENT

REPLACEMENT
Open the compartment door.
Compartment to floor bolts (74).
2. Compartment from the vehicle.
1.

1. Compartment to the vehicle.
2. Compartment to the floor bolts (74).
Figure 17Floor Panel Trim Panel
Figure 18Rear Scuff Plate
53.
54.
55.
56.
57.
58.
59.
60.
61.
Rear H e a d e r M o ld in g
H e a d lin e r
W in d s h ie ld U p p e r G a rn ish M o ld in g
S cre w
W in d s h ie ld G a rn is h M o ld in g
S cre w
S id e W in d o w G a rn is h M o ld in g
S crew
L ock P illa r G a rn is h M o ld in g
B-09071
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
Lock C y lin d e r
Bezel
C ase A s s e m b ly
D o o r A s s e m b ly
D o o r S to p
S crew
H in g e
S trik e r
N ut
B o lt
Bum per
C o m p a rtm e n t A s s e m b ly
B o lt
B o lt
S u p p o rt
B-09072
Figure 21Floor Compartment
SUBURBAN MODEL
Figure 22Corner Garnish Molding
CARPET REPLACEMENT
8.
9.
10.
11.

2 . Front and rear door scuff plates (figure 5).
3. Kick panel.
HEADLINER AND TRIM

REPLACEMENT
4. Rear corner garnish molding screws (77) and the

molding (78).
5. Rear lock pillar garnish molding screws (79) and the
6.
7.
8.
9.
10.
11.
molding (80).
Front lock pillar garnish molding screws (81) and the
molding (82).
Body side trim panel screws (83) and the panel (84).
Front scuff plate screws (85) and the plate (86).
Rear scuff plate screws (87) and the plate (88).
Carpet (89) from the vehicle.

Carpet (89) to the vehicle.
Rear scuff plate (88) and the screws (87).
Front scuff plate (86) and the screws (85).
Body side trim panel (84) and the screws.
Front lock pillar garnish molding (82) and the screws
(81).
Rear lock pillar garnish molding (80) and the screws
(79).
Rear corner garnish molding (78) and the screws (77).

Kick panel.
Front and rear door scuff plates (figure 5).
Seats and seat belts. Refer to SEATS (SEC. 10A1).

molding (91).
2. Side header garnish molding screws (92) and the
molding (93).
(94).
4. Rear roof header molding screws (95) and the molding
(96).
5. Side header rear garnish molding screws (97) and the
molding (98) (if equipped).
6. Upper side garnish molding screws (99) and the
molding (100) (if equipped).
7. Roof inner trim pane! screws (101) and the panel (102).
- 4-
1. Headliner (103) to the vehicle.

2. Roof inner trim panel (102) and screws (101).

ROOF REAR HEADER
TRIM PANEL
1. Lower trim panel screws (104) and the lower panel
(105).
2. Upper trim panel screws (106) and the upper panel
(107).

1. Upper trim panel (107) and the screws (106).
2. Lower trim panel (105) and the screws (104).
Figure 24Front Lock Pillar Molding

3. Upper side garnish molding (100) and screws (99) (if
equipped).
4. Side header rear garnish molding (98) and screws (97)
(if equipped).
5. Rear roof header molding (96) and screws (95).
6. Windshield garnish molding (94) and screws.
7. Side header garnish molding (93) and screws (92).
8. Windshield upper garnish molding (91) and screws
(90).
Figure 25Side Trim Panel
Figure 27Carpet
90. S crew
91. W in d s h ie ld U p p e r G a rn ish M o ld in g
92. S crew
93. S ide H e a d e r G a rn is h M o ld in g
94. W in d s h ie ld G a rn is h M o ld in g
95. S crew
96.
97.
98.
101.
102.
103.
Rear R oof H ea d e r M o ld in g
S crew
S ide H ea de r Rear G a rn ish M o ld in g
S crew
R oo f In n e r Trim Panel
H e a d lin e r
Figure 29Side Garnish Molding
B-09039
Figure 30Rear Header Lower Trim Panel
B-09040
Figure 31Rear Header Upper Trim Panel
G MODEL INTERIOR TRIM
CARPET REPLACEMENT
1. Seats. Refer to SEATS (SEC. 10A2).

2. Front carpet retainer (110).
Front door scuff plate (112).
Front step panel mat (if equipped) (114).
Carpet from the dash retainers (108).
Bend the retainers away from the dash.

Front carpet (115) from the vehicle.
7. Side door scuff plate (116).
8. Side door mat (if equipped) (118).
9. Carpet to side door screws (119).
10. Rear door scuff plate (121).
11. Front trim panel (123).
12. Rear trim panel (125).
13. Rear corner panel (127).
14. Rear carpet from the vehicle.
8. Side door scuff plate (116).

9. Front carpet (115) to the vehicle.
10. Carpet to the dash retainers (108).
Bend the retainers over the carpet.
11. Front step panel mat (if equipped) (114).
13. Front carpet retainer (110).
14. Seats. Refer to SEATS (SEC. 10A2).
HEADLINER REPLACEMENT
1. Upper window trim that supports the headliner. Refer
to Interior Trim Replacement.
2. Headliner retainer bow (if equipped).
Pull the bow (128) from the retainer.
3. Retainer bolts (129) and the retainers (130).
Shift the headliner from side to side to disengage
the headliner from the clips.
- Install or Connect (Figures 32 through 41)

1.
2.
3.
4.
5.
6.
7.
Rear carpet to the vehicle.

Rear corner panel (127).
Rear trim panel (125).
Front trim panel (123).
Rear door scuff plate (121).
Carpet to side door screws (119).
Side door mat (if equipped) (118).

1. Headliner (131) to the vehicle.
Place the headliner into the roof clips.
2. Retainers (130) to the headliner, and the retainer bolts
(129).
3. Headliner retainer bow (if equipped).
INTERIOR TRIM 10A4419
Push the bow (128) onto the retainer.

4. Upper window trim that supports the headliner. Refer
to Interior Trim Replacement.
INTERIOR TRIM REPLACEMENT

++
1. Lock pillar garnish molding screws and the lock pillar

garnish molding (figure 43).
2. Front door hinge pillar molding screws and the front
door hinge pillar molding (figure 44).
3. Sunshade screws and the sunshade (figure 45).
4. Front header garnish molding screws and the front
header garnish molding (figure 46).
5. Roof side rail garnish molding (figure 47). For vehicles
with intermediate doors only.
48) For
vehicles with the sliding side door only.
Lower lock pillar garnish molding sc
and the
molding (figure 49).
Body side front garnish molding sc
and the
Roof rear header garnish molding sc
anc the
and the
Body rear corner garnish molding sc
and the
12. Body side front trim panel screws and the trim panel
(figure 39).
Pull the panel from the retainers.
13. Body side rear trim panel screws and the trim panel
(figure 40).
14. Body side trim rear corner panel screws and the panel
(figure 41).
1. Body side trim rear panel and screws (figure 41).
2. Body side rear trim panel and screws (figure 40).
3. Body side front trim panel and screws (figure 39).

4. Body side rear garnish molding and screws (figure 52).
5. Body rear corner garnish molding and screws (figure
51).
6. Roof rear head garnish molding and screws (figure 50).
7. Body side front garnish molding and screws (figure
49).
8. Lower lock pillar garnish molding and screws (figure
49).
9. Roof side header garnish molding and screws (figure
48). For vehicles with the sliding side door only.
10. Roof side rail garnish molding and screws (figure 47).
For vehicles with intermediate doors only.
11. Front header garnish molding and screws (figure 46).
12. Sunshade and screws (figure 45).
Figure 38Rear Door Scuff Plates
13. Front door hinge pillar molding and screws (figure 44).
14. Lock pillar garnish molding and screws (figure 43).

ENGINE COVER REPLACEMENT
1. Instrum ent panel lower extension screws (150),
washers (151), and shims (152).
2. Instrument panel lower extension (153).
3. Engine cover (158) to floor panel bolts (156).
4. Clamp (157) from the pin (155).
5. Engine cover (158) from the vehicle.

1.
2.
3.
4.
5.
Engine cover (158) to the vehicle.

Clamp (157) to the pin (155).
Engine cover (158) to floor panel bolts (156).
Instrument panel lower extension (153).
Instrum ent panel lower extension screws (150),
washers (151) and shims (152).
122. Screw
123. F ront Trim Panel
B-09123
Figure 39Front Trim Panel
124. Screw
125. Rear Trim Panel
B-09137
Figure 40Rear Trim Panel
Figure 41Rear Corner Panel
128.
129.
130.
131.
B ow
B o lt
R e ta in e r
H e a d lin e r
128
Figure 42Headliner Retainer
B-09151
Figure 44Hinge Pillar Molding
Figure 46Front Header Garnish Molding
Figure 47Roof Rear Rail Garnish Molding
146
144
144. S crew
145. L ow er Lock P illa r
G a rn ish M o ld in g
146. S cre w
|
147. F ro n t S ide
G a rn ish M o ld in g
* 145
B-09070
Figure 49Front Garnish Moldings
Figure 51Rear Corner Garnish Molding
Figure 50Rear Header Garnish Molding
151
151
150.
151.
152.
153.
Screw
_____
W asher
Shim s
Instrum ent Panel Lower Extension
Figure 53Instrument Panel Lower Extension
150
150
B-09054
Figure 54Engine Cover
---------------------------------------,
10A5-1
SECTION 10A5
END GATE
CONTENTS
S U BJE C T
Fender Side M odels.............................................................................................
End Gate Replacement.....................................................................................
Fleet Side M odels...............................................................................................
End Gate Replacement....................................................................................
Handle And Latch Replacement......................................................................
Utility Vehicle Models.........................................................................................
Torque Rod Replacement................................................................................
Hinge Replacement.........................................................................................
End Gate Cover Replacement..........................................................................
Handle And Control Assembly Replacement.................................................
Latch Replacement.........................................................................................
Regulator Replacement....................................................................................
Window Motor And Blockout Switch Replacement.......................................
Sash Assembly Replacement..........................................................................
Run Channel Replacement..............................................................................
End Gate Outside Crank Replacement..........................................................
Window Glass Seal Replacement....................................................................
Weatherstrip Replacement..............................................................................
Utility Vehicle Removable Top............................................................................
Removable Top Replacement................................................................ .
Suburban Models.................................................................................................
Torque Rod Replacement................... ..........................................................
Hinge Replacement.........................................................................................
End Gate Trim And Cover Panel Replacement...............................................
Handle And Control Assembly Replacement.................................................
Latch Replacement.........................................................................................
Regulator Replacement...................................................................................
Blockout Switch Replacement.......................................................................
Sash Assembly Replacement..........................................................................
Run Channel Replacement................................. ............................................
End Gate Outside Crank Replacement..........................................................
Window Glass Seal Replacement....................................................................
Weatherstrip Replacement..............................................................................
PA G E
.........................................10A, >- 2
.........................................10A, 5- 2
.........................................10A j- 2
.........................................10A >- 2
.........................................10A >- 2
.........................................10A >- 4
.........................................10A >- 4
.........................................10A 5- 5
.........................................10A j- 6
.........................................10A 5- 6
.........................................10A 5- 6
.........................................10A 5- 7
.........................................10A 5- 8
.........................................10A 5- 9
.........................................10A 5-10
.........................................10A 5-11
.........................................10A 5-11
.........................................10A 5-11
.........................................10A 5-11
.........................................10A 5-12
.........................................10A 5-12
..................................... . .10A 5-13
.........................................10A 5-13
.........................................10A 5-13
........................................10A 5-13
.........................................10A 5-15
.........................................10A 5-15
.........................................10A 5-16
.........................................10A 5-16
.........................................10A 5-17
.........................................10A 5-17
......................... .............. 10A 5-17
.........................................10A 5-17
.........................................10A 5-17
.........................................10A 5-18
10A5-2 END GATE
FENDER SIDE MODELS

END GATE REPLACEMENT
Open the end gate and support it with a table or other
suitable support.
Fender to end gate bolt (6) and washer (7).
End gate (4), and bushing (5) from the vehicle.
Chain (3) to fender nut (1), washer (2), and eye bolt.

1.
2.
3.
4.
Chain (3) with eye bolt to the fender.

Washer (2) and nut (1) to the eye bolt.
End gate (4) and bushing (5) to the vehicle.
Fender to end gate washer (7), and bolt (6).
Anti-rattle bumper must seat fully against vertical
surface of tab (159).
1.
2.
3.
4.
N ut
S p rin g W a sh er
C h a in A s s e m b ly
End G ate
5.
6.
7.
159.
B u s h in g
B o lt
W asher
A n ti-R a ttle B u m p e r
F-02459
Figure 1Fender Side End Gate Components
FLEET SIDE MODELS

4- +
Open the end gate and support it with a table or other

suitable support.
Link and striker plate (8) to fender bolts (17).
Link and striker (8) from the end gate.
Rotate the link until it aligns with the tab (9) on

the end gate, and pull it from the end gate.
Hinge (14) to end gate bolts (13).
End gate (12) from the vehicle.
Inner hinge half (A).
Hinge (14) to fender bolts (16).
7. Outer hinge half (B).
8. Bumper (10) to fender screws (11).
9. Bumpers (10) from the vehicle.

Bumpers (10) to the vehicle.
Bumper (10) to fastener screws (11).
Outer hinge half (B).
Hinge (14) to fender bolts (16).
Inner hinge half (A).
End gate (12) to the vehicle.
Hinge (14) to end gate bolts (13).
8 . Link and striker (8) to the end gate.
Place the slot on the link in line with the tab (9)
on the end gate, and place the link onto the end
gate. Pivot the link into its proper position.
9. Link and striker to the fender.
10. Link and striker to fender bolts (17).
HANDLE AND LATCH

REPLACEMENT
Lower and support the end gate with a table or other
suitable support.
Latch rods (19) from the clips (20).
End gate to handle bolts (22).
Handle (21) from the end gate.
Link from the end gate.
Refer to End Gate Replacement.
Latch (18) to end gate bolts (23).
Latch (18) from the vehicle.

Latch (18) to the vehicle.
Latch (18) to end gate bolts (23).
END GATE 10A5-3
8. L in k A nd
S trik e r Plate A s s e m b ly
9. Tab
10. B u m p e r
11. S crew
12. End G ate
13. B o lt
14. H in g e
16. B o lt
17. B o lt
A. In n e r H in g e H a lf
B. O u te r H ing e H a lf
B-09023
Figure 2Fleet Side End Gate Components

3. Link to the end gate.
Refer to End Gate Replacement.
4. Handle (21) to the end gate.
5. End gate to handle bolts (22).
6. Latch rods (19) to the clips (20).
10A5-4 END GATE
UTILITY VEHICLE MODELS

24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
B o lt
O u te r B ra cke t
Torque Rod
B o lt
S ile n c e r
In n e r B ra cke t
S tu d
Fram e
N ut
S ile n c e r
B-09034
Figure 4Utility Vehicle Torque Rod

|++| Remove or Disconnect (Figures 4, 5, and 6)
The end gate must be in the closed position.
1. Torque rod to frame stud (30) and nut (32).
Allow the torque rod to swing down.
Open the end gate, and support it with a table or other

suitable support.
2. Electrical wiring harness (if equipped). Refer to End
Gate Cover Replacement for access to the harness.
3. Cable (34) to end gate opening bolts (37), spacers (36),
and washers (35).
END GATE 10A5-5
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Cable
W asher
Spacer
Bolt
W asher
Spring
W asher
Bolt
Screw
Guide
B-09035
Figure 5Cable Assembly Components

Torque rod bracket bolts (24) and brackets (25).
Hinge (49) to floor panel bolts (48) from the under side
of the vehicle.
End gate from the vehicle.
Lift the end gate from the body.
Guide the torque rods over the gravel deflectors
to prevent damage.

End gate to the vehicle.
Guide the torque rods over the gravel deflectors
to prevent damage.
Insert the hinges into the floor panel slots.
Hinge (49) to floor pan bolts (48) to the under side of
the vehicle.
Torque rod brackets (25) and bolts (24).
Cable (34) to the end gate opening with bolts (37),
spacers (36), and washers (35).
Electrical wiring harness (if equipped). Refer to End
Gate Cover Replacement for access to the harness.
Close the end gate.
Torque rod to frame stud (30) and nut (32).
Torque rods onto the studs.
TORQUE ROD REPLACEMENT

1.
2.
3.
4.
End gate. Refer to End Gate Replacement.

End gate cover.
End gate to torque rod inner bracket bolts (27).
Torque rod (26) with silencers (28) from the end gate.
10A5-6 END GATE
Inner bracket (29) from the end gate.
1.
2.
3.
4.
5.
1. End gate cover (50).
Torque rod (26) with silencers (28) to the end gate.

Inner bracket (29) to the torque rod.
End gate cover.
2. End gate cover screws (51).
HANDLE AND CONTROL

HINGE REPLACEMENT
Lower the end gate.
1. Hinge to body bolts (48) for the hinge to be removed
only.
Loosen the hinge to body bolts (48) on the opposite
hinge.
2. Hinge to end gate bolts (47) for the hinge to be
removed.
Pull the end gate away from the body several inches
and remove the hinge from the body.
Lift the end gate slightly to allow removal of the hinge
from the end gate.
Lift the end gate slightly and install the hinge to the
ond gate.
Pull the end gate away from the body several inches,
and insert the hinge into the body.
1. Hinge to end gate bolts (47).
2. Hinge to body bolts (48).
Tighten the hinge to body bolts on the opposite hinge.
END GATE COVER

REPLACEMENT
1. End gate cover screws (51).
2. End gate cover (50).
1. End gate cover.
2 . Control rod (64) from the handle (61).

3. Handle to end gate screws (62).
4. Handle (61) from the end gate.
5. Right and left latch rods (65) from the control
assembly.
6. Control assembly to end gate bolts (60).
7. Control assembly (55) from the end gate.
8. Window lockout rod spring (54).
9. Lockout rod (53) to end gate bolts (52).
10. Lockout rod (53) from the end gate.

Lockout rod (53) to the end gate.
The bottom of the rod must fit into the clip at the
base of the end gate.
2. Lockout rod (53) to end gate bolts (52).

3. Window lockout rod spring (54).
4. Control assembly (55) to the end gate.
6 . R ight and left latch rods (65) from the control
assembly.
8 . Handle to end gate screws (62).
9. Control rod (64) to the handle (61).
10. End gate cover.
END GATE 10A5-7
Figure 8Handle and Control Assembly
LATCH REPLACEMENT

1. Latch (66) with rod to the end gate.

1. End gate cover.
2. Latch (66) to end gate screws (67).
2. Right or left latch rod (65) from the control assembly.
3. Right or left latch rod (65) to the control assembly.
3. Latch (66) to end gate screws (6.7).
4. End gate cover.
4. Latch (66) from the end gate.
Figure 9Latch Components
10A5-8 END GATE
69.
70.
71.
72.
73.
74.
75.
R e g u la to r
B o lt
Sash Rail
B o lt
Sash A s s e m b ly
F ille r
G la ss
75
B-09142
Figure 10Regular and Sash Components
REGULATOR REPLACEMENT
MANUAL REGULATOR
l+ +| Remove or Disconnect (Figure 10)
CAUTION: Step 4 must be performed if the gear

box is removed or disengaged from the
regulator lift arms. The left arms are under
tension from the counterbalance spring, and
can cause injury if the gear box is removed
without locking the sector gears in place.
1. End gate cover.

2. Control assembly. Refer to Handle And Control
3. Sash assem bly (73). Refer to Sash Assem bly
Replacement.
4. Regulator (69) to end gate bolts (70).
4. Drill a 3.1 mm (Vs-inch) diameter hole through the

sector gear and back plate. Install a sheet metal
tapping screw into the hole to lock the sector gears in
position.
5. Regulator (69) from the end gate.
I++J Install or Connect (Figure 10)

1. Regulator (69) to the end gate.
Replacement.
5. Drive cable (77) at regulator (76).

8. Gear assembly (80) to regulator bolts.
9. Gear assembly (80) from the regulator (76).

1. Gear box (80) to the regulator (76).

2. Gear box (80) to regulator bolts.
5. End gate cover.
POWER REGULATOR
1. End gate cover.
Replacement.

5. Drive cable (77) to the regulator (76).
Remove the sheet metal screw.
Replacement.
7. Control assembly. Refer to Handle and Control
8. End gate cover.
END GATE 10A5-9
76.
77.
78.
79.
80.
R e g u la to r
C a b le A s s e m b ly
B o lt
M o to r A s s e m b ly
G e ar A s s e m b ly
B-09143
Figure 11Power Regulator Components
WINDOW MOTOR AND BLOCKOUT

SWITCH REPLACEMENT
1. End gate panel.
2. Wiring harness from the motor and switch.
3. Cable from the motor.
4. End gate to motor bolts (103).
5. Motor (104) from the end gate.
6. Latch containing the blockout switch from the end
gate. Refer to Latch Replacement.
7. Blockout switch (106) to latch bolts (105).
8. Blockout switch (106) from the latch.
1. Blockout switch (106) to the latch.
2. Blockout switch (106) to latch bolts (105).
3. Latch to the end gate. Refer to Latch Replacement.
4. Motor (104) to the end gate.
5. End gate to motor bolts (103).
6. Cable to the motor.
7. Wiring harness to the motor and the switch.
8. End gate panel.
10A5-10 END GATE
SASH ASSEMBLY REPLACEMENT

1. Window run channel caps (figure 13).
2. Inner and outer window glass seals. Refer to Window
Glass Seal Replacement.
3. End gate cover.
Regulate the window so that the sash channel bolts
(72) are accessable.
4. Sash (73) to sash channel bolts (72).
85.
86.
87.
88.
89.
90.
91.
Nut
Bezel
G asket
H andle A ssem bly
C lip
Bezel
Gasket
92.
93.
94.
95.
96.
97.
98.
5. Sash (73) with glass (75) from the end gate.

6. Sash rails (71) from the regulator (69).
|K | Install or Connect (Figure 10)

1. Sash rails (71) to the regulator (69).
2. Sash (73) with glass (75) to the end gate.
4. End gate cover.
Cover
G asket
Lock C ylinder
Retainer
C lutch
Pawl
Spring
B-09058
Figure 14Window Control Components
END GATE 10A5-11

6. Window run channel caps (figure 13).
RUN CHANNEL REPLACEMENT
-* Install or Connect (Figure 14)

1. Crank (88) and bezel (86) to the end gate.
2. Crank to end gate nuts (85).
3. Handle and control assembly. Refer to Handle And
Control Assembly Replacement.

1. Window run-channel caps (83).
Completely lower the window.
2. Run-channel (81) from the end gate.
Pull the channel from the end gate. Twist the
channel to clear the window opening.

1. Run-channel (81) to the end gate.
Twist the channel into the window opening.
2. Run-channel (81) to end gate bolts (82).
3. Window run-channel caps (83).
END GATE OUTSIDE CRANK

REPLACEMENT
3. Crank (88) and bezel (86) from the end gate.
WINDOW GLASS SEAL

REPLACEMENT
Lower the window.
Inner or outer seal by prying the clips from the end
gate.

Inner or outer seal by pressing the clips into the holes
in the end gate.
Weatherstrip from the end gate using 3M Release
Agent (or equivalent).

Weatherstrip to the end gate using 3M Weatherstrip
10A5-12 END GATE
UTILITY VEHICLE REMOVABLE TOP

5. Side trim panel rear attaching screws.
Remove twelve screws on the left side.
Remove eleven screws on the right side.
Pull the panel away only far enough to gain access to
the hidden top bolt.
6. Hidden bolts (115).
7. The removable top (111).
With the assistance of helpers, carefully lift the
top from the vehicle. Do not allow the sides to
bend.
0
Figure 17Removable TopAccess Plate
Components
REMOVABLE TOP REPLACEMENT

B

1.
2.
3.
4.
Access plate (108) and dome lamp wiring harness.

Lower the end gate.
Top (111) to roof mounting bolts (110) and (114).
Top (111) to side panel mounting bolts (113) and (112).
Upper tire brace bolt and the upper brace.
Reinstall the brace after the top is removed.
To prevent damage to the top and to ensure proper

weatherstrip sealing, the following procedure must be fol
lowed.
Remove the upper spare tire brace.
1. The top onto the vehicle.
Use the two rear guide pins as locators.
2. Top to roof mounting bolts (114).
3. Top to side panel mounting bolts (112).
Start with the bolts nearest the end gate, and
work towards the cab.
Do not install the second bolt from the rear on
the right side at this time.
Do not install the bolts (113) nearest the cab.
Loosen the top (111) to roof mounting bolts (114).
4. Top to side panel mounting bolts (113).
5. Top to roof mounting bolts (110) and (114).
6. Hidden bolts (115).
7. Trim panel screws to the right and left trim panels.
8. The upper spare tire brace with the remaining bolt.
9. Dome lamp wiring harness, and access plate (108).
END GATE 10A5-13
Figure 18Removable Top Components
SUBURBAN MODELS
|++| Remove or Disconnect (Figures 19, 20, and
21)
Lower the end gate.
1. Torque rod bracket (119).
2. Wiring harness (if equipped). Refer to End Gate Trim
And Cover Panel Replacement for access to the
wiring harness.
3. Hinge access cover (131) and seal (132).
4. End gate to hinge bolts (133).
Lift the end gate to the almost closed position.
5. Support cable (136) to end gate bolt (142) and washer
(143).
6. End gate with torque rod from the vehicle.
-+ Install or Connect (Figures 19, 20 and 21)

1. End gate with torque rod (117) to the vehicle.
2. Support cable (136) to end gate washer (143) and bolt
(142).
3. End gate to hinge bolts (133).
4. Hinge cover seal (132) and access cover (131).
5. Wiring harness (if equipped). Refer to End Gate Trim
And Cover Panel Replacement for access to the
wiring harness.
6. Torque rod bracket (119).
TORQUE ROD REPLACEMENT

1.
2.
3.
4.
5.
6.

Trim panel (if equipped) and the cover panel.
End gate to torque rod outer bracket bolts (122).
Inner (118) and outer (119) brackets from the end gate.
Torque rod (117) from the end gate.

1.
2.
3.
4.
5.
6.
7.
Torque rod (117) to the end gate.

Outer brackets (117) to the end gate.
Outer bracket bolts (122).
Inner bracket (118) to the end gate.
Inner bracket bolts (126).
The cover panel and trim panel (if equipped).
HINGE REPLACEMENT
Lower the end gate.
1. Hinge to body bolts (134) for the hinge to be removed.
Loosen the hinge to body bolts (134) on the opposite
hinge.
10A5-14 END GATE
B-09077
Figure 19SuburbanTorque Rod Components
128.
129.
130.
131.
132.
133.
134.
135.
S trik e r
W a sh er
S crew
C over
Seal
B o lt
B o lt
H in g e
B-09078
Hinge cover screws (130) and covers (131).

Hinge to end gate bolts (133) for the hinge to be
removed.
Pull the end gate away from the body several inches
and remove the hinge from the body.
Lift the end gate slightly to allow removal of the hinge
from the end gate.
4-
Lift the end gate slightly and install the hinge to the
end gate.
Pull the end gate away from the body several inches,
and insert the hinge into the body.
1. Hinge to end gate bolts (133).
2. Hinge to body bolts (134).
Tighten the hinge to body bolts on the opposite hinge.
3. Hinge covers (131) and cover screws (130).
END GATE 10A5-15
136.
137.
138.
139.
140.
141.
142.
143.
C able
B o lt
W a sh er
S p rin g
Plug
W a sh er
B o lt
W a sh e r
142
B-09079
Figure 21Cable Assembly Components
Figure 22Trim Panel Components
10A5-16 END GATE
146.
147.
148.
149.
150.
151.
S crew
C over
B o lt
C o n tro l A s s e m b ly
L a tc h Rod
Lever A s s e m b ly
B-09081
Figure 23End Gate Cover and Control Assembly Components
END GATE TRIM AND COVER

PANEL REPLACEMENT
1. Trim panel screws (145).
2. Trim panel (144).
Slide the panel away from the glass opening.
Note the position of the cover panel screws. Five of the
holes in the cover panel are also holes for the trim
panel.
3. Cover panel screws (146).
4. Cover panel (147).

1.
2.
3.
4.
Cover panel (147).

Cover panel screws (146).
Trim panel (144).
Trim panel screws (145).
HANDLE AND CONTROL

1. Trim panel (if equipped) and the cover panel.
2. Control rod (154) from the handle (159).
4. Handle (159) from the end gate.
assembly.
7. Control assembly (149) from the end gate.

1. Control assembly (149) to the end gate.
assembly.
6. Control rod (154) to the handle (159).
7. End gate cover and trim panel (if equipped).
LATCH REPLACEMENT
[<"| Remove or Disconnect (Figure 24)
1. Trim panel (if equipped) and the cover panel.
2. Right or left latch rods (150) from the control assembly.
4. Latch (153) from the end gate.
END GATE 10A5-17
Figure 24Handle and Latch Components

1. Latch (153) with rod to the end gate.
3. Right or left latch rod (150) to the control assembly.
4. Cover panel and trim panel (if equipped).
REGULATOR REPLACEMENT
MANUAL REGULATOR
1. Trim panel (if equipped) and cover panel.
Replacement.

Replacement.
POWER REGULATOR
1. Trim panel (if equipped) and end gate cover.
Replacement.
4. Wiring harness from the motor.

CAUTION: Step 7 must be performed if the gear

box is removed or disengaged from the
regulator lift arms. The lift arms are under
tension from the counterbalance spring, and
can cause injury if the gear box is removed
without locking the sector gear in place.
7. Drill a 3.1 mm (Vs-inch) diameter hole through the
sector gear and back plate. Install a sheet metal
tapping screw into the hole to lock the sector gears in
position.
8. Motor to regulator bolts.
9. Motor from the regulator.

1. Motor to the regulator.
2. Motor to regulator bolts.
Remove the sheet metal screw.
5. Wiring harness to the motor.
Replacement.
8. Trim panel (if equipped) and end gate cover.
10A5-18 END GATE
RUN CHANNEL REPLACEMENT
BLOCKOUT SWITCH
REPLACEMENT
Completely lower the window.

2. Run-channel (156) from the end gate.
Pull the channel from the end gate. Twist the
channel to clear the window opening.
1. Trim panel (if equipped) and the end gate cover.

2. The rig h t la tch
Replacement.
assem bly.
R efer
to
Latch
3. Wiring harness from the switch.
4. Switch from the latch.
1. Run-channel (156) to the end gate.

Twist the channel into the window opening.
1. Switch to the latch.
2. Wiring harness to the switch.
END GATE OUTSIDE

CRANK REPLACEMENT
3. The right latch assembly to the end gate. Refer to

Latch Replacement.
|<+| Remove or Disconnect (Figure 14)

3. Crank (88) and gasket (87) from the end gate.
SASH ASSEMBLY REPLACEMENT

2. Trim panel (if equipped) and cover panel.
Regulate the window so that the sash channel bolts
(72) are accessable.
4. Sash (73) with glass (75) from the end gate.
5. Sash rails (71) from the regulator (69).
0
M
1.
2.
3.
4.
5.

Sash rails (71) to the regulator (69).
Sash (73) with glass (75) to the end gate.
Sash (73) to sash channel bolts (72).
End gate cover and trim panel.
Inner and outer window glass seals. Refer to Window

1. Crank (88) and gasket (87) to the end gate.
END GATE 10A5-19

WINDOW GLASS SEAL
REPLACEMENT
Lower the window.
1. Trim panel (if equipped).
The inner seal is attached to the trim panel,
w hen e qu ip pe d , and re p la ce m e n t is not
recommended.
2. Inner or outer seals by prying the clips from the end
gate.
rs
1. Inner or outer seal by pressing the clips into the holes

in the end gate.
2. Trim panel (if equipped).
1. Weatherstrip screws (158).
2. Weatherstrip from the end gate using 3M Release
Agent (or equivalent).

1. Weatherstrip to the end gate using 3M Weatherstrip
2. Weatherstrip screws (158).
Figure 26Weatherstrip Components
10A5-20 END GATE
SECTION
PAGE
A
A/C Com ponentsG Series
Accum ulator R eplacem ent........................................1B-50
Blower Motor R ep lace m e nt................................... ,.1B-54
Blower Switch R e p la ce m e n t................................... 1B-57
Condenser R eplacem ent..........................................1B-50
Control Assem bly R e p la c e m e n t............................ 1B-55
Defroster Duct R eplace m e nt................................... 1B-57
Ductwork R e p la ce m e n t............................................ 1B-57
Evaporator Core (Diesel) R eplacem ent................. 1B-53
Evaporator Core R eplacem ent.................................1B-53
Heater Core R ep lace m e nt....................................... 1B-51
Orifice Replacem ent...................................................1B-53
Refrigerant-12 Hose R o u tin g ................................... 1B-58
Relay R e p la ce m e n t...................................................1B-57
Resistor R e p la ce m e n t.............................................. 1B-57
Temperature Door Cable A d ju s tm e n t....................1B-55
Temperature Door Cable R eplacem ent................. 1B-57
Vacuum Lines E n g in e ............................................ 1B-57
Vacuum Tank R eplacem ent..................................... 1B-57
A/C Components R/V Series
Accumulator Replacem ent........................................1B-35
Actuator-Plenum Side Vent Replacem ent............. 1B-37
Blower Assembly R eplacem ent...............................1B-35
Blower Switch R e p la ce m e n t................................... 1B-40
Condenser R eplacem ent..........................................1B-34
Control Assembly R e p la c e m e n t.............................1B-39
Evaporator Core R eplacem ent.................................1B-36
Fuse R eplacem ent.....................................................1B-43
Heater Core R eplacem ent........................................1B-36
Orifice Replacement...................................................1B-36
Plenum Valve Replacem ent..................................... 1B-37
Refrigerant-12 Hose R o u tin g ................................... 1B-43
Relay R e p la c e m e n t...................................................1B-41
Resistor R e p la c e m e n t.............................................. 1B-41
Selector Duct R eplacem ent..................................... 1B-36
Temperature Door Cable A d ju s tm e n t....................1B-40
Vacuum Line Replacement D a s h ......................1B-43
Vacuum Line Replacement E ngine......................1B-43
Vacuum Tank R eplacem ent..................................... 1B-41
A/C Charging Station M e th o d ..................................... 1B-26
A/C Compressor D iag no sis..........................................1B-27
A/C Compressor Replacement ( G ) ............................ 1B-30
A/C Compressor Replacement ( R / V ) ........................ 1B-29
A/C Condenser D iag no sis............................................1B-27
A/C Electrical/Vacuum Trouble D iag no sis..................1B-18
A/C Evacuation and Charging Procedures............... 1B-23
A/C Evaporator D ia g n o sis............................................1B-27
A/C Expansion Valve D ia g n o s is ................................. 1B-27
A/C Functional Test R/V & G ................................... 1B-4
A/C Gage C alibration.....................................................1B-26
A/C Handling R efrigerant-12..........................................1B-9
A/C Handling Refrigerant Lines and F ittin g s ............. 1B-9
A/C M aintaining Chemical Stability...............................1B-9
A/C Periodic Maintenance and S e rvicin g ....................1B-4
A/C Pressure Sensing S w itc h ..................................... 1B-13
A/C Quick-Check P ro c e d u re ................................... 1B-11
A/C Rear Interior Roof Mounted Systems
(Suburban & G Series) D escription.......................... 1B-3
A/C Rear Roof Mounted System G S eries............. 1B-63
A/C Refrigerant and Oil C a p a c ity ................................. 1B-9
A/C Refrigerant Drum M ethod..................................... 1B-26
SECTION
PAGE
A/C Refrigerant-11 Flushing Procedure......................1B-29

A/C Refrigerant-12 Operating C haracteristics............. 1B-9
A/C Refrigerant System D ia g n o s is .............................1 B -11
A/C Special Tools........................................................... 1B-67
A/C S p e cifica tio n s......................................................... 1B-65
A/C System Com ponents................................................ 1B-4
A/C System Description.................................................. 1B-3
A/C System P Series
A/C System Performance T e s t..................................... 1B-11
A/C System Operation R/V & G ...............................1B-4
A/C Temperature and Pressure R ela tion ship s........... 1B-9
A/C Testing the Refrigerant System ............................ 1B-11
A/C Vacuum System C h e c k ....................................... 1B-26
A/C Vacuum System D iagnosis................................... 1B-23
Accelerator C ontrols.......................................................6C-16
Accelerator Control C a b le ............................................6C-16
Accelerator P e d a l........................................................... 6C-16
A/C Electrical C irc u its .................................................. 8A-48
Advance Pin Hole Plug Seal
Replacement (D ie se l).............................................. 6C2-17
Advance Piston Replacement (D ie s e l)....................6C2-18
Advance Piston Seals Replacement (D ie s e l).........6C2-17
Air C le a n e r.........................................................................6C-2
AIR D iagnosis................................................................6E8-21
Air Filter Element R e p la c e m e n t................................... 6C-2
Air Injection Reaction (A IR ) ....................................... 6E8-19
Air Valve Link Adjustm ent
(M4ME and M4MEF M od els).................................6C1-45
Air Valve Return Spring Adjustm ent
(M4ME and M4MEF M o d e ls ).................................6C1-41
Aluminum R adiator.......................................................6B2-15
Anaerobic Gasket Eliminator, U s in g ............................ 6A-2
Auxiliary Cooling Fan R eplacem ent.......................... 6B1-14
Auxiliary Heater Components G
Blower Motor Replacement ......................................1A-25
Coolant-Control Valve R ep la ce m e n t......................1A-26
Heater Core R eplacem ent....................................... 1A-26
Resistor R e p la c e m e n t.............................................. 1A-26
Auxiliary Heater Components R/V
Blower Motor R e p la c e m e n t..................................... 1A-17
Blower Switch R eplacem ent..................................... 1A-17
Coolant-Control Valve Replacem ent........................ 1A-17
Heater Core R e p la c e m e n t....................................... 1A-17
Resistor R eplacem ent................................................ 1A-17
Axle Joint Component R e p la c e m e n t.......................... 4C-4
Axle Shaft Replacement, F ro n t......... ..................
.4C-2
Axle Shaft, Oil Seal and Bearing Replacement
(8 V2 and 9 1/2-inch Ring G e a r ) .................................4B1-9
Axle Shaft Replacement Full Floating Axle
(9 3/4 and 101/2-inch Ring G ear)...............................4B1-14
Axle Shaft Replacement (12-inch Ring G e a r).........4B1-18
Axle Vent Replacement (12-inch Ring G e a r ) .........4B1-18
B
Ball Joint, Lower, I.F.S.....................................................3C-17
Ball Joint, Upper, I.F.S.................................................... 3C-19
Ball Joints (V10/1500 and 20/2500 Models O n ly ).. .3C-48
Battery C a b le s .................................................................. 6 D-6
Battery Charging P ro ce d u re s........................................6D-5
Battery Description........................................................... 6D-2
Battery-General In fo rm a tio n ............... ..........................6D-3
Battery R eplacem ent.......................................... ......... 6 D -6
SECTION
PAGE
Bearing Adjustm ent Full Floating Axle

Bearing Adjustment (12-inch Ring G ear)................. 4B1-18
Bleeding, Hydraulic C lu tc h ............................................ 7C-9
Bleeding the Brake Hydraulic S y s te m ........................ 5A-5
Bleeding the Hydro-Boost System ...............................5A1-7
Blower and Air Inlet A s s e m b ly ..................................... 1A-2
Brake A d ju stm e n t......................................................... 5A2-10
Brake Backing Plate Replacement (8 V2 and
9 1/2-inch Ring G e a r ) ................................................ 4B1-11
Brake Caliper R ebuilding.............................................. 5A2-6
Brake Drum S e rvice .....................................................5A2-10
Brake Lining Replacement (Drum B rakes)............... 5A2-9
Brake Pedal A s s e m b ly ...................................................5A-13
Brake Pedal R e p la ce m e n t............................................ 5A-13
Brake Pedal Rod R e p la ce m e n t................................... 5A-15
Brake Pedal Travel C h e c k ............................................ 5A-13
Brake Pipes and H o s e s ...................................................5A-6
Brake System D ia g n o s is ................................................ 5A-2
Bumpers, G M o d e l......................................................... 2A-18
Bumpers, P M o d e l......................................................... 2A-15
Bumpers, R/V M o d e l....................................................... 2A-7
c
Cab Mount R eplacem ent.............................................. 2B-18
Camshaft Lobe Lift, Measuring
(4 .3 L )...........................................................................6A3-17
(Small B lo ck )..............................................................6A4-17
(7 .4 L )...........................................................................6A5-13
( 4 .8 L )...........................................................................6A7-14
Camshaft Replacement
(4 .3 L )...........................................................................6A3-17
(Small B lo ck)..............................................................6A4-17
(7.4 L ) ...........................................................................6A5-13
(6 .2 L ) ........................................................................... 6A6-14
( 4 .8 L )........................................................................... 6A7-15
Carburetor Adjustm ent ( 1 M E F ) ................................. 6C1-17
Carburetor, 1 B B L ......................................................... 6C1-15
Carburetor Diagnosis, 1 B B L ........................................6C1-7
Carburetor, 4 B B L ....................................................... 6C1-37
Carburetor Diagnosis, 4 B B L..................................... 6C1-28
Carburetor Identification
(M4ME and M4MEF M o d e ls)................................. 6C1-21
Carburetor Model 1 M E F .............................................. 6C1-2
Carburetor Models M4ME and M 4 M E F ..................6C1-21
Carburetor Mounting Torque
(M4ME and M4MEF M odels)................................. 6C1-38
Carburetor Replacement (1 M E F ).............................6C1-17
Carburetor Replacement (M4ME and M4MEF) . . .6C1-38
Carburetor Special T o o ls ............................................ 6C1-48
Carburetor S p e c ific a tio n s ..........................................6C1-47
Carbureted Engine Fuel F ilte rs ..................................... 6C-2
Catalytic Converter R e p la ce m e n t................................. 6F-4
CDR Valve C heck........................................................... 6E9-4
CDR Valve R eplacem ent.............................................. 6E9-5
Charging System C S -1 3 0 ........................................6D-12
Charging System S I...................................................6D-10
Chassis E lectrical..............................................................8 B-1
Choke Checking Procedure
(M4ME and M4MEF M odels).................................6C1-37
Choke Link and Fast Idle Cam Adjustment
SECTION
PAGE
Choke Stat Lever Adjustm ent

(M3ME and M3MEF M od els)................................. 6C1-42
Circuit Check Glow Plug S y s te m ...........................6D-16
Circuit D ia g n o s is ..............................................................8A-4
Circuit R e p a ir.................................................................... 8A-6
Clutch Assembly and Pilot B e a rin g .............................7C-11
Clutch D ia g n o s is ..............................................................7C-3
Clutch Inspe ction ..............................................................7C-2
Clutch L in k a g e .................................................................. 7C-7
Clutch Pedal Free Travel A d ju s tm e n t.......................... 7C-9
Clutch Pedal, M a n u a l.....................................................7C-4
Clutch Pedal, H ydraulic...................................................7C-4
Clutch S p e c ific a tio n s ..................................................... 7C-15
Coil Springs, I.F.S.............................................................3C-17
Combination V a lv e ........................................................... 5A-7
Compression Check
Diesel E n g in e ..............................................................6A-10
Gasoline E n g in e ............................................................6A-5
Connecting Rod and Piston Replacement
(4.3 L)........................................................................... 6A3-20
(Small B lo ck).............................................................. 6A4-19
(7.4 L ) ........................................................................... 6A5-15
(6 .2 L )........................................................................... 6A6-21
(4 .8 L ) ........................................................................... 6A7-16
Control Arm, Lower, I.F.S............................ ................3C-24
Control Arm, Upper, I.F .S ............................................. 3C-25
Control Arm Pivot Shaft and Bushings, Lower, I.F.S.3C-20
Control Arm Pivot Shaft and Bushings, Upper, I.F.S.3C-23
Coolant Level Indicator D iagnosis............................... 6B1-3
Coolant Recovery S y s te m ...................... ................6B2-14
Coolant Recovery Tank R eplace m e nt........................ 6B1-6
Cooling System Capacities
Blazer/Jimmy, S u b u rb a n ............................................ OB-2
Cooling System Capacities
Forward C o n tr o l............................................................0B-3
Cooling System Capacities G V a n ...........................OB-5
Cooling System Capacities Pickup M o d e ls ........... OB-4
Cooling System D iagnosis............................................ 6B1-5
Cowl Vent Grille Replacement (G M o d e l)..................2B-15
Cowl Vent Grille Replacement (R/V M o d e l)................2B-4
Crankcase Ventilation System (6.2L D iesel)............. 6E9-4
Cranking C irc u it.............................................................. 6D-22
Cranking Speed Check (6 .2 L )......................................6A-10
Cranking System D escription........................................6D-19
Cranking System M ainten an ce ................................... 6D-27
Crankshaft Gear Replacement (4.8L)........................ 6A7-19
Crankshaft Replacement
(4.3 L)........................................................................... 6A3-23
(Small Block).............................................................. 6A4-22
(7.4 L ) ........................................................................... 6A5-18
(6.2L)........................................................................... 6A6-24
(4.8 L ) ........................................................................... 6A7-20
Cross Lever, C lu tc h ..........................................................7C-8
Current Drain T e s t............................................................6D-5
Cylinder Head Replacement
(4 .3 L )........................................................................... 6A3-12
(Small B lo c k )..............................................................6A4-12
(7.4 L ) ............................................................................. 6A5-7
(6.2 L)............................................................................. 6A6-9
(4 .8 L )............................................................................. 6A7-9
SECTION
PAGE
D
Deaeration Tank Replacem ent..................................... 6B1-6
Detent Switch (THM 400).............................................. 7A-67
Diagnosis
,
AIR ...............................................................................6E8-21
Battery.............................................................................6D-4
Carburetor, 1 B B L .......................................................6C1-7
Carburetor, 4 B B L.....................................................6C1-28
C irc u it.............................................................................8A-4
C lu tc h .............................................................................7C-3
C o o lin g ........................................................................ 6B1-2
Diesel E n g in e ................................................................6A-8
Door L o c k .................................................................... 8A-23
D riv e lin e ........................................................................ 4A-3
E E C S .......................................................................... 6E8-17
E F E .............................................................................6E8-35
EGR.............................................................................6E8-33
Front A x le ...................................................................... 4C-2
Front Side M arker.......................................................8B-10
Front S uspension......................................................... 3C-2
Fuel G a g e ...................................................................... 8C-4
Fuel Tank Selector V a lv e ..........................................6C-13
Gas E n gin e ....................................................................6A-2
Glow Plug Electrical S y s te m ................................... 6D-16
H e a d la m p ...................................................................... 8B-6
Heater Circuit D ia g n o s is ............................................1A-8
Heater S y s te m ............................................................. 1A-9
Hydraulic L ifte rs ........................................................... 6A-6
Ignition System ........................................................... 6D-36
Insufficient Heat D ia g n o s is ....................................... 1A-5
Marker L a m p ............................................................... 8B-10
Manual S tee rin g ......................................................... 3B2-2
Oil Pressure G a g e .......................................................8C-5
Parking L a m p s ............................................................. 8B-8
P C V .............................................................................6E8-39
Power S tee rin g ........................................................... 3B3-5
Power W in d o w ........................................................... 8A-24
Rear A x le ....................................................................4B1-2
Rear Lighting S ystem s.............................................. 8B-17
Spark P lu g s ............................................................... 6D-39
S p e e d o m e te r................................................................8C-3
Steering C olum n......................................................... 3B4-2
Steering Linkage......................................................... 3B1-2
Temperature G a g e .......................................................8C-6
THERMAC..................................................................6E8-41
T h e rm o s ta t..................................................................6B1-3
Torque C o n ve rte r........................................................ 4C-11
Torque Converter C lutch ............................................7A-12
Transmission, Automatic.............................................. 7A-6
Transmission, M anual.................................................. 7B-2
Transmission, THM 400 ............................................7A-16
Transmission, THM 700 R -4..................................... 7A-35
T R C .............................................................................6E8-43
Vacuum P u m p ............................................................. 6H-1
Water In Fuel Light.................................................. 6C-3
Wheels and T ire s ......................................................... 3E-3
Wheel B e a rin g s ........................................................... 3C-3
Windshield Washer.....................................................8A-35
Windshield W ip e r................................... ................... 8A-26
W iper D e la y ............................................................... 8A-38
Diesel Engine D ia g n o sis................................................ 6A-8
Diesel Fuel F ilte rs ........................................................... 6C-3
SECTION
PAGE
Diesel Fuel Filter Assembly Component

Replacement..................................................................6C-5
Diesel Fuel Filter R eplacem ent..................................... 6C-4
Diesel Fuel Injection Special T oo ls.......................... 6C2-21
Diesel Fuel Injection S p e c ific a tio n s ........................ 6C2-20
Diesel Fuel System C ontam ination...............................6C-8
Diesel Glow Plug Electrical System
D e s c rip tio n ..................................................................6D-15
Diesel Idle Speed A djustm ent..................................... 6C2-2
Diesel Throttle Position Switch Adjustment
(LH6 Engine With 700 R4 T ra n sm ission )............. 6C2-3
Differential C a p a c itie s .....................................................0B-1
Dipstick Tube Replacement (6.2L)............................ 6A6-16
Disc Brakes...................................................................... 5A2-1
Disc Brake Lining In spection....................................... 5A2-1
Disc Brake Lining R e p la c e m e n t.................................5A2-2
D istributor........................................................................ 6D-33
Distributor R e p la c e m e n t.............................................. 6D-41
Distributor/Timing System for TBI-Equipped
V e h ic le s ...................................................................... 6D-36
Doors (G Model Front)
Door and Hinge R ep lace m e nt............................ 10A1-32
Outside Handle R e p la c e m e n t............................ 10A1-40
Lock R e p la c e m e n t................................................ 10A1-39
Power Lock R eplacem ent..................................... 10A1-40
Trim Panel R eplacem ent........................................10A1-33
Vent R e p la c e m e n t................................................ 10A1-35
Window Regulator R e p la ce m e n t........................ 10A1-38
Window R eplacem ent............................................10A1-36
Doors (G Model Intermediate)
Door and Hinge R ep la ce m e n t............................ 10A1-42
Trim P a n e l................................................................10A1-44
Doors (G Model Rear)
Door and Hinge R e p la ce m e n t............................ 10A1-63
Lock R eplacem ent...................................................10A1-70
Outside Handle R eplacem ent...............................10A1-70
Trim Panel R eplacem ent........................................10A1-64
Doors (G Model Sliding)
Door and Hinge R ep la ce m e n t............................ 10A1-53
Trim Panel R eplacem ent....................................... 10A1-58
Window R eplacem ent...........................................'10A1-58
Doors (RV Model F ro n t).............................................. 10A1-4
Door and Hinge R eplacem ent...............................10A1-4
Trim Panel Replacement..........................................10A1-4
Vent/Window R e p la c e m e n t................................... 10A1-5
Lock Replacement.................................................. 10A1-10
Outside Rear View Mirror Replacement............. 10A1-13
Power Lock Motor R eplacem ent.......................... 10A1-10
Window Regulator R ep lace m e nt.......................... 10A1-9
Doors (RV Model Side Rear)
Door and Hinge R e p la c e m e n t.............................10A1-14
Trim Panel R eplacem ent....................................... 10A1-16
Window Regulator R e p la c e m e n t........................ 10A1-19
Window R ep lace m e nt............................................10A1-17
Doors (RV Model Rear)
Door and Hinge R e p la ce m e n t........................ .. .10A1-23
SECTION
PAGE
Trim Panel Replacem ent....................................... 10A1-25

W indow R eplacem ent............................................10A1-25
Draining the Diesel Engine Fuel F ilte r........................ 6C-3
Draining the Fuel Tank.....................................................6C-7
Drivability S ym p to m s.....................................................6E8-8
Drive Belt R e p la ce m e n t.............................................. 6B1-10
Drive Pinion Oil Seal Replacement
(12-Inch Ring G ear).................................................. 4B1-19
Drive Shaft Seal Replacement (Diesel)....................6C2-19
Drum Brakes.................................................................... 5A2-9
E
Early Fuel Evaporation (E F E )................................... 6E8-35
EECS D ia g n o sis........................................................... 6E8-17
EFE D ioa gn osis........................................................... 6E8-35
EGR D iagnosis..............................................................6E8-33
EGR System Check (6.2L D ie s e l)...............................6E9-6
EGR Valve Replacement (6.2L D ie s e l)...................... 6E9-7
Electric Choke (1 M E F ) .............................................. 6C1-15
Electrical C irc u its ..............................................................8A-2
Electrical Systems, C a b ................................................... 8A-9
Electrical Tests G e ne ra to r....................................... 6D-10
Emissions, Carb...............................................................6E8-2
Emissions Components, Carb...................................... 6E8-5
End Gate
Fender Side M o d e ls ........... .....................................10A5-2
Fleet Side M odels.....................................................10A5-2
Suburban M o d e ls ............. .....................................10A5-13
Utility Vehicle M odels.............................................. 10A5-4
Engine Block H e a te rs ...................................................8D-28
Engine Code Identification.............................................. OB-1
Engine Crankcase Capacities
Blazer/Jimmy, S u b u rb a n ....................................... .. .0B-2
Forward C o n tr o l........................................................... OB-3
G V a n ............................................................................. OB-5
Pickup M o d e ls ..............................................................OB-4
Engine Electrical System ................................................ 6D-2
Engine Electrical System Specifications....................6D-77
Engine Emission Classification VIN C o d e ..................OB-8
Engine Gaskets, R e p la cin g ............................................6A-2
Engine Lubrication
(4.3L)............................................................................. 6A3-2
(Small Block)................................................................6A4-2
(7.4 L ) ............................................................................. 6A5-3
(6.2 L)............................................................................. 6A6-2
(4 .8 L )............................................................................. 6A7-2
Engine Replacement
(4.3 L)............................................ .............................. 6A3-24
(Small Block)..............................................................6A4-23
(7.4 L ) ...........................................................................6A5-22
(6.2 L)...........................................................................6A6-28
(4 .8 L )...........................................................................6A7-21
Engine Mountings
(4 .3 L )...........................................................................6A3-23
(Small Block)............................................................. 6A4-22
(7.4 L ) ...........................................................................6A5-19
(6.2 L)...........................................................................6A6-25
(4 .8 L )...........................................................................6A7-21
Engine Wire Harness.....................................................6D-52
SECTION
PAGE
Engines with T B I ............................................................6D-33

EPR Vacuum Actuator R eplacem ent.......................... 6E9-7
EPR/EGR Solenoid R eplacem ent............................... 6E9-7
Evaporator Emissions Control System
(EEC S).........................................................................6E8-16
Exhaust Gas Recirculation (EGR).............................6E8-32
Exhaust Gas Recirculation System
(6.2L D ie s e l)................................................................ 6E9-5
Exhaust Inspection........................................................... 6F-2
Exhaust Manifold Replacement
(4 .3 L )........................................................................... 6A3-11
(Small B lo ck)..............................................................6A4-10
(6.2 L)............................................................................. 6A6-3
(7 .4 L )............................................................................. 6A5-7
Exhaust Parts, Installing...................................................6F-2
Exhaust S pecifications...................................................6F-10
Exhaust System D ia g n o s is ............................................ 6F-2
F
Fan and Fan Clutch R eplacem ent.............................6B1-13
Fan Clutch D iagnosis..................................................... 6B1-2
Fan Shroud R e p lace m e nt............................................ 6B2-6
Float Adjustment (M4ME and M4MEF M o d e ls ). . .6C1-40
Float Level-External Check
Fluids and L u b ric a n ts ...................................................OB-24
Flushing the Brake Hydraulic S ystem .......................... 5A-6
Flushing the Cooling System ........................................6B1-6
Flywheel Replacement
(4.3 L)........................................................................... 6A3-23
(Small Block)..............................................................6A4-22
(7.4 L ) ...........................................................................6A5-18
(4 .8 L )........................................................................... 6A7-20
Frame A lig n m e n t..............................................................2A-4
Frame D ia g n o s is ..............................................................2A-2
Frame Straightening......................................................... 2A-5
Front Axle Assembly Replacem ent............................... 4C-3
Front Axle Capacities
Front Axle Capacities Pickup M o d e ls ....................OB-4
Front Axle D ia g n o sis....................................................... 4C-2
Front Axle, I-B eam ......................................................... 3C-34
Front Axle Specifications.................................................4C-8
Front Cover Replacement
(4 .3 L )........................................................................... 6A3-14
(Small B lo ck)..............................................................6A4-14
(7 .4 L )........................................................................... 6A4-14
(6 .2 L )........................................................................... 6A6-13
(4.8L)............................................................................. 6A7-11
Front End A lig n m e n t....................................................... 3A-2
Front End Alignment R e q u ire m e n ts.............................3A-3
Front End Alignment S p e c ific a tio n s .............................3A-6
Front End Panel Replacement (G M o d e l)..................2B-17
Front End Sheet Metal Cross Panel Replacement
(G M odel).......................................................................2B-17
Front Fender Replacement (R/V M odel)...................... 2B-6
Front Suspension, D ia g n o s is ........................................3C-2
Front Suspension, S p e c ific a tio n s............................... 3C-51
Fuel Filter R e p la c e m e n t.................................................6C-2
Fuel Filter Replacement
Fuel Gage D iagnosis....................................................... 8C-4
SECTION
PAGE
Fuel Gage R ep lace m e nt................................................ 8C-9

Fuel Gage Sending U n i t .............................................. 6C-13
Fuel Gage Sending Unit R eplacem ent...................... 6C-13
Fuel L in e s .........................................................................6C-10
Fuel Pump Replacem ent................................................ 6C-6
Fuel Pump Tests (Carbureted E n g in e )........................ 6C-5
Fuel Pump Tests (Diesel E n g in e )................................. 6C-5
Fuel System Cleaning (Carbureted E ngine)............... 6C-8
Fuel System Cleaning (Diesel E n g in e )........................ 6C-9
Fuel System S p e c ific a tio n s ..........................................6C-17
Fuel T a n k ...........................................................................6C-7
Fuel Tank Capacities
Fuel Tank Capacities Forward C o n tro l....................0B-3
Fuel Tank Capacities G V a n ........................ .............0B-5
Fuel Tank Capacities Pickup M o d e ls ...................... 0B-4
Fuel Tank Filler N e c k .....................................................6C-10
Fuel Tank Leak T e s t....................................................... 6C-10
Fuel Tank P u rg in g ........................................................... 6C-9
Fuel Tank R eplacem ent................................................ 6C-10
Fuel Tank Selector V a lv e .............................................. 6C-13
Fuel Tank Selector Valve Replacem ent...................... 6C-13
Full Floating Axle (93/4 and
101/2-inch Ring G e a r).............................................. 4B1-14
Full Floating Axle (12-inch Ring A x le )...................... 4B1-18
Fuse Block
R V ................................................................................. 8A-14
V an................................................................................. 8A-17
G
G a ge s................................................................................. 8C-9
Gasoline Engine Mechanical D ia g n o sis...................... 6A-2
Generator R eplacem ent................................................ 6D-14
Glow Plug A fte rsta rt.......................................................6D-19
Glow Plug Inhibit S w itc h .............................................. 6D-16
Glow Plug S y s te m ..................................... ................... 6D-19
Governor, Automatic T ra n sm issio n .............................7A-68
Grille and Molding Replacement (R/V M o d e l)........... 2B-5
Grille Replacement (G M o d e l)..................................... 2B-15
H
H e a d la m p ...........................................................................8B-7
Headlamp D ia g n o s is .......................................................8B-6
Heater Electrical C ircu its.............................................. 8A-48
Heating Components G
Cable A djustm ent.......................................................1A-22
Control Assembly R e p la c e m e n t............................ 1A-22
Control Cable R eplacem ent..................................... 1A-22
Blower Motor R e p la ce m e n t..................................... 1A-18
Blower Switch R e p la ce m e n t................................... 1A-22
Distributor and Defroster Duct
R eplacem ent................................................................1A-21
Heater Core R e p la ce m e n t........................................1A-19
Heater Distributor Case R eplacem ent....................1A-21
Heater Hose R o u tin g ................................................ 1A-18
Resistor R ep la ce m e n t.............................................. 1A-22
Vent R ep lace m e nt.....................................................1A-22
Heating Components R/V
Blower Motor R e p la ce m e n t..................................... 1A-10
Blower Switch R eplacem ent..................................... 1A-14
Cable A d ju stm e n t.......................................................1A-14
SECTION
PAGE
Control Assembly R eplacem ent...............................1A-11

Control Cable R eplacem ent..................................... 1A-12
Heater Distributor Case and
Core R e p la c e m e n t.....................................................1A-10
Heater Hose R o u tin g ................................................ 1A-10
Resistor R eplacem ent................................................ 1A-14
Vent R e p la c e m e n t.....................................................1A-14
Height Sensing Brake Proportioning Valve..................5A-9
Hood Hinge Replacement (R/V M odel)........................ 2B-2
Hood Hinge Replacement (G M o d e l) ........................ 2B-13
Hood Ornament Replacement (R/V M o d e l)............... 2B-4
Hood Release Cable Replacement
(R/V M odel).................................................................... 2B-3
Hood Release Cable Replacement
(G Model)...................................................................... 2B-15
Hood Replacement (G M o d e l)..................................... 2B-13
Hood Replacement (R/V M o d e l)................................... 2B-2
Housing Pressure Cold Advance (Diesel)................. 6C2-4
Hub and Drum Assembly Replacement Full Floating
Axle (93/4 and 101/2~inch Ring G e a r ) ....................4B1-14
Hydraulic Brake B o o s te r.............................................. 5A1-4
Hydraulic Head Seal Replacement (D ie s e l)........... 6C2-18
Hydraulic Lifters D ia g n o s is ............................................ 6A-6
Hydraulic Lifter Replacement
(4.3L)............................................................................. 6A3-9
(Small Block)................................................................6A4-9
(7.4 L ) ............................................................................. 6A5-6
(6.2L)................................. ........................................... 6A6-6
(4 .8 L )............................................................................. 6A7-6
Hydro-Boost R eplacem ent............................................ 5A1-4
Hydro-Boost System D ia g n o s is ................................... 5A1-1
Hydro-Boost System Tests............................................ 5A1-2
Hydrometer Test................................................................ 6D-4
I
Idle Mixture Adjustment (Heavy-Duty Emissions
Vehicle Only) M4ME and M4MEF M o d e ls .........6C1-39
Idle Speed Adjustm ent
Idle Solenoid (1 M EF)...................................................6C1-16
Idle Stop S o le n o id ....................................................... 6C1-37
Idler Arm Adjustment (P30(32) M otorhom e)............. 3B1-2
Idler Arm Inspection....................................................... 3B1-2
Idler Arm R e p la c e m e n t................................................ 3B1-3
Ignition System for Carbureted E ngine......................6D-36
Ignition System Service P re c a u tio n s ........................ 6D-40
Ignition S w itc h ................................................................8C-16
Ignition Switch Replacement (R, V, G M o d e ls ).. . .3B4-18
Ignition T im in g ................................................................6D-41
Injection Line Replacement (D iesel).......................... 6C2-4
Injection Nozzles (Diesel)............................................ 6C2-10
Injection Nozzle Replacement (D ie s e l)....................6C2-10
Injection Nozzle Tests (D iesel)................................... 6C2-10
Injection Pump Off-Vehicle Service (D ie sel)........... 6C2-17
Injection Pump On-Vehicle Service (D ie sel)........... 6C2-10
Injection Pump Replacement (Diesel)........................ 6C2-5
Injection Timing Adjustm ent (D ie s e l)........................ 6C2-8
Instrument C lu s te r......................................................... 8C-15
Intake and Exhaust Manifold Replacement (4.8L) . .6A7-7
Intake Manifold Replacement
(4 .3 L ).............................................................................6A3-7
(Small Block)................................................................6A4-8
SECTION
PAGE
(6.2L).............................................................................6A6-3
(7.4 L).............................................................................6A5-5
Interior Trim
G M odels..................................................................10A4-18
R/V M o d e ls ............................................................... 10A4-1
Suburban M o d e l.....................................................10A4-13
L
Lamp S w itch ....................................................................8C-16
Leaf Spring and Bushings, 4 W.D............................... 3C-49
Leaf Spring Assembly R eplacem ent............................ 3D-9
Leaf Spring Eye Bushing R e p la ce m e n t....................3D-10
Leaf Springs, I-Beam .....................................................3C-34
License Plate Bracket R ep la ce m e n t.......................... 2A-13
Load Test B a tte ry .......................................................6D-4
Locking Hub Rebuild Procedure, M anual....................4C-8
Locking Hub Component R ep la ce m e n t......................4C-4
Locking Hub Replacement, M a n u a l............................ 4C-7
Locking Hub to the Wheel Adjustment, A u to m a tic.. .4C-7
Lubrication Points Conventional, Forward
Control M o d e ls ............................................................. OB-6
Lubrication Points Four Wheel Drive M odels...........0B-6
Lubrication Points G Van..............................................0B-7
M
Main Bearing Replacement
(4.3L).......................................................................... 6A3-22
(Small Block)............................................................. 6A4-21
(7.4 L ) .......................................................................... 6A5-17
(6.2L).......................................................................... 6A6-22
(4 .8 L ).......................................................................... 6A7-18
Maintenance Schedules.................................................. 0B-7
Manual Steering Gear M aintenance.......................... 3B2-3
Manual Steering Gear S p ecifica tion s........................ 3B2-7
Manual Steering System D ia g n o s is .......................... 3B2-2
Marker Lam p.................................................................... 8B-11
Marker Lamp D iagnosis................................................ 8B-10
Marking TDC on the Front Housing (D ie s e l)...........6C2-8
Master Cylinder and Reservoir, C lu tc h ........................ 7C-5
Master C y lin d e rs ........................................................... 5A-24
Master Cylinder Bench Bleeding.................................5A-26
Master Cylinder R eplacem ent..................................... 5A-24
Minimum-Maximum Governor Replacement
(Diesel Fuel Injection)..............................................6C2-13
o
Oil Filter Bypass Valve Replacement
(4.3 L).......................................................................... 6A3-23
(Small Block)............................................................. 6A4-20
(7.4 L ) .......................................................................... 6A5-18
(6.2L).......................................................................... 6A6-24
(4 .8 L ).......................................................................... 6A7-20
Oil Pan Replacement
(4 .3 L ).......................................................................... 6A3-15
(Small B lock)............................................................. 6A4-14
(7.4 L ) .......................................................................... 6A5-10
(6 .2 L ).......................................................................... 6A6-17
(4 .8 L ).......................................................................... 6A7-12
Oil Pressure Gage D ia g n o s is ....................................... 8C-5
Oil Pressure Gage R eplacem ent.................................8C-13
SECTION
PAGE
Oil Pressure Gage S ensor............................................ 8C-14

Oil Pump Drive Replacement (6 .2 L )........................ 6A6-12
Oil Pump Replacement
(4 .3 L )...........................................................................6A3-16
(Small B lo c k )............................................................. 6A4-15
(7.4 L).............................................................................6A5-11
(6 .2 L )...........................................................................6A6-18
( 4 .8 L )...........................................................................6A7-12
P
Parking Brake A d justm e nt............................................ 5A-22
Parking Brake Cable R e p la ce m e n t............................ 5A-18
Parking Brake Pedal or Handle R eplacem ent........... 5A-17
Parking Brake S y s te m ...................................................5A-17
Parking L a m p .................................................................... 8B-9
Parking Lamp D ia g n o s is................................................ 8 B -8
PCV D iagnosis............................................................. 6E8-39
Pinion Flange, Dust Deflector/Oil Seal Replacement
(8 V2 and 9 1/2-inch Ring Gear).................................4B1-12
Pinion Oil Seal/Companion Flange Replacement
Full Floating Axle (9 3/4 and
101/2-inch Ring G e a r ) .............................................. 4B1-17
Pitman Arm R ep lace m e nt............................................3B1-5
Pitman Shaft Seal R eplacem ent.................................3B2-5
Positive Crankcase Ventilation (P C V )......................6E8-39
Power Door L o c k ........................................................... 8A-24
Power Lock D ia g n o sis.................................................. 8A-23
Power Steering D iag no sis............................................3B3-5
Power Steering F lu s h .................................................. 3B3-12
Power Steering G e a r .................................................. 3B3-13
Power Steering Gear Adjustm ents............................ 3B3-17
Power Steering Pum p.................................................. 3B3-19
Power Steering System B le e d in g .............................3B3-12
Power Steering System T e s t........................................3B3-8
Power W in d o w ................................................................8A-26
Power Window D ia g n o s is ............................................ 8A-24
Pressure Testing the Injection Pump
( D ie s e l)...................................................................... 6C2-19
Primary Hood Latch Replacement (G M odel)...........2B-13
Primary Hood Latch Replacement (R/V M od el).........2B-2
Primary Side Vacuum Break Adjustm ent
Propeller S h a ft.................................................................. 4A-1
Propeller Shaft Balance C h e c k ..................................... 4A-5
Propeller Shaft Brake R e p la ce m e n t.......................... 5A-22
Propeller Shaft Replacement (Front D rive)..................4A-7
Propeller Shaft Replacement (Rear D riv e )..................4A-6
Propeller Shaft Runout C heck....................................... 4A-5
Pump Adjustm ent (M4ME and M4MEF Models) . .6C1-41
Pump Cover Seal and/or Guide Stud Seal
Replacement (Diesel Fuel In je c tio n )....................6C2-12
Pushrod Cover Replacement (4.8L).............................6A7-6
R
Radiator Support Replacement (R/V M odel)............. 2B-10
Rear Axle Assembly Replacement (All A x le s ) .........4B1-8
Rear Axle Diagnosis....................................................... 4B1-2
Rear Axle S p e cifica tio n s............................................ 4B1-20
Rear Crankshaft Seal Retainer Replacement
(4 .3 L )........................................................................ 76A3-16
(Small B lo ck)............................................................. 6A4-16
SECTION
PAGE
Rear Crankshaft Oil Seal Replacement

(4.3L) . . . .................................................................... 6A3-16
(Small B lo ck)..............................................................6A4-15
(7.4 L)............................................................................. 6A5-11
(6 .2 L )...........................................................................6A6-18
(4 .8 L )...........................................................................6A7-13
Rear Extension Oil Seal, Automatic
Transm ission................................................................7A-73
Rear Fender Replacement (R/V M o d e l)...................... 2B-8
Rear Lighting S e rv ic e ...................................................8B-21
Rear Lighting D iagnosis................................................ 8B-17
Rear Lighting System s...................................................8B-11
Rear Oil Seal, Manual Transm ission.............................7B-3
Rear Suspension S p e cifica tio n s................................. 3D-12
Relay Rod R ep la ce m e n t.............................................. 3B1-4
Road Testing the B ra k e s.................................................5A-2
Rocker Arm and Pushrod Replacement
(4.3 L)............................................................................. 6A3-5
(Small Block)................................................................6A4-5
(7.4 L ) ............................................................................. 6A5-3
(4 .8 L )............................................................................. 6A7-4
Rocker Arm Cover Replacement
(4.3L)............................................................................. 6A3-5
(Small Block)................................................................6A4-5
(7.4 L ) ............................................................................. 6A5-3
(6.2L)............................................................................. 6A6-4
(4 .8 L )............................................................................. 6A7-4
Rocker Arm, Shaft, and Pushrod
Replacement (6 .2 L )...................................................6A6-4
Rocker Arm Stud Replacement
(4 .3 L )...........................................................................6A3-10
(Small B lko ck)........................................................... 6A4-10
(7.4 L ) ............................................................................. 6A5-7
(4 .8 L )............................................................................. 6A7-8
Rotor Servicing................................................................5A2-6
RTV Sealer, U s in g ........................................................... 6A-2
s
Seat Adjuster Diagnosis.............................................. 10A2-2
Seat B e lts ...................................................................... 10A2-7
Seats
G Model Center and R e a r................................... 10A2-26
G Model F ront......................................................... 10A2-23
RV Model Front......................................................... 10A2-3
RV Model R e a r....................................................... 10A2-13
Suburban Model C enter..........................................10A2-8
Secondary Hood Latch and Spring Replacement
(G Model)...................................................................... 2B-14
Secondary Hood Latch and Spring Replacement
(RV M o d e l).................................................................... 2B-3
Secondary (Slave) Cylinder and Hydraulic
Line, C lutch.................................................................... 7C-6
Secondary Side Vacuum Break Adjustment
Secondary Throttle Lockout Adjustment
Selector Valve D ia g n o sis.............................................. 6C-13
Servo, 2-4 (THM 7 00-R 4).............................................. 7A-71
Semi Floating Rear Axle (8 V2 and
9 1/a Ring G e a r)........................................................... 4B1-9
Sheet Metal Adjustments (R/V M odel)........................ 2B-11
Sheet Metal Unit Replacement (R/V M o d e l)............. 2B-11
SECTION
PAGE
Sheet Metal Vertical Support

Replacement (G M o d e l)............................................ 2B-17
Shift Control, Manual Transmission...............................7B-7
Shift Linkage Adjustment,
Manual T ransm ission...................................................7B-6
Shift Linkage, Automatic T ransm ission...................... 7A-63
Shift Linkage, Manual T ransm ission.............................7B-5
Shock Absorber Bench T e s t..........................................3C-3
Shock Absorber, I-B e a m .............................................. 3C-28
Shock Absorber, I.F.S....................................................... 3C-8
Shock Absorber, 4 W.D.................................................. 3C-36
Shock Absorber R e p la c e m e n t..................................... 3D-8
Shutdown and/or Cold Advance Solenoid
Replacement (D ie se l).............................................. 6C2-16
Side Cover Gasket Replacement (D iesel)............... 6C2-17
Side Cover, Manual Transm ission.................................7B-8
Spark P lu g s .................................................................... 6D-35
Spark Plug W ire s........................................................... 6D-35
Spark Plug Wires Service........................................6D-42
Spark Plug Wire R ep la ce m e n t................................... 6D-42
Specifications (Engine)
(4.3L)........................................................................... 6A3-28
(Small Block)..............................................................6A4-32
(7.4L)...........................................................................6A5-27
(6.2L)...........................................................................6A6-33
(4 .8 L )...........................................................................6A7-25
Speedometer Cable Core R eplacem ent...................... 8C-7
Speedometer Diagnosis...................................................8C-3
Speedometer Drive Gear, Manual
Transmission.................................................................. 7B-3
Speedometer Drive Gear/Vehicle
Speed S ensor..............................................................7A-67
Speedometer R eplacem ent............................................ 8C-7
Spindle, 4 W.D..................................................................3C-41
Spring Assembly Replacement (R/V M o d e l)............. 2B-2
Stabilizer Bar R eplacem ent............................................ 3D-8
Stabilizer Bar, I-B e a m ...................................................3C-30
Stabilizer Bar, I.F.S............................................................ 3C-8
Stabilizer Bar, 4 W.D.......................................................3C-36
Starter Motor N o is e ....................................................... 6D-24
Starter Motor R eplacem ent..........................................6D-27
Starter Motor Service.....................................................6D-27
Steering Arm, Knuckle and Spindle, I-B e a m ........... 3C-33
Steering Column D iagnosis..........................................3B4-2
Steering Column (G Model) R e p la c e m e n t............. 3B4-16
Steering Column Lock C ylinder Replacement
(R, V, G M o d e ls )....................................................... 3B4-17
Steering Column Lower Bearing Adjustment
-P(42) M odels........................................................... 3B4-42
Steering Column Lower Bearing Replacement
-P (42 M o d e ls ........................................................... 3B4-42
Steering Column Lower Bearing Adjustment
(Standard).................................................................. 3B4-23
Steering Column Replacement (Standard)P(42) M odels............................... .............................. 3B4-38
Steering Column (RV Model) R e p la c e m e n t........... 3B4-15
Steering Column Shift Tube A djustm entP(42) M odels..............................................................3B4-41
Steering Column Special T ools................................. 3B4-45
Steering Column S p e c ific a tio n s ...............................3B4-44
Steering Column (Standard) Unit R epairP(42) M odels..............................................................3B4-42
Steering Column Unit R epairStandard (R, V, G M o d e ls )............................., . . .3B4-19
SECTION
PAGE
Steering Column Unit R epairTilt (R, V, G M odels)................................................ 3B4-26

Steering Column Upper Bearing ReplacementP(42) Models............................................................. 3B4-39
Steering Connecting Rod Replacement
(P30(32) Motorhome)................................................ 3B1-11
Steering Connecting Rod Replacement (V and P30(00)
FS3 M o d e ls )............................................................. 3B1-10
Steering Flexible Coupling R e p lace m e nt............... 3B4-14
Steering Gear Adjustments, M anual.......................... 3B2-6
Steering Gear High Point Centering,
M a n u a l........................................................................ 3B2-7
Steering Gear Replacement, M a n u a l........................ 3B2-3
Steering Intermediate Shaft R e p la ce m e n t............. 3B4-13
Steering Intermediate Shaft Unit R epairP(42) M odels............................................................. 3B4-43
Steering Knuckle and Arm, 4 W.D...............................3C-45
Steering Knuckle, I.F.S................................................... 3C-15
Steering Linkage D iagnosis..........................................3B1-2
Steering Linkage Specifications.................................3B1-13
Steering Shock Absorber Inspection.......................... 3B1-6
Steering Shock Absorber R e p la ce m e n t....................3B1-7
Steering Wheel Inspection......................................... 3B4-12
Stoplamp S w itch............................................................. 5A-16
Suspension Unit, I.F.S....................................................3C-26
T
Temperature Gage D ia g n o s is ....................................... 8C-6
Temperature Gage R eplacem ent.................................8C-11
THERMAC D iagnosis.................................................. 6E8-41
Thermostat D ia g n o s is .................................................. 6B1-3
Thermostat Housing Crossover R e m o va l................. 6B1-8
Thermostatic Air Cleaner (TH E R M AC )....................6E8-40
Thermostat R eplacem ent.............................................. 6B1-7
Throttle K ic k e r ............................................................. 6C1-38
Throttle Kicker Adjustm ent
Throttle Position Switch Adjustment
(6.2L D ie s e l)................................................................6E9-8
Throttle Return Control (TR C )...................................6E8-43
Throttle Shaft Seal Replacement
(Diesel Fuel Injection).............................................. 6C2-14
Tie Rod Replacement (R, G P20 and
30(42) Models)............................................................. 3B1-7
Tie Rod Replacement (V and P30(00)
FS3 M o d e ls )................................................................3B1-8
Tilt Steering Column Unit R epairP(32) M odels............................................................. 3B4-38
Tilt Steering Column Replacem entP(32) M odels............................................................. 3B4-33
Tilt Steering Column Bearing Housing ReplacementP(32) M odels............................................................. 3B4-35
Timing Gear Cover Replacement (4.8L)....................6A7-11
Tire Load Limits and Inflation P re s s u re ......................3E-1
Tone Alarm Switch (Steering Column) Replacement
(R, V, G M o d e ls ).......................................................3B4-18
Torque Converter Clutch D iagnosis............................ 7A-12
Torque Converter D iagnosis..........................................7A-11
T o rs io n a l D a m p e r and F ro n t C ra n k s h a ft S e al
Replacement
(4 .3 L )...........................................................................6A3-13
(Small B lo ck)............................................................. 6A4-13
SECTION
PAGE
(7.4 L)............................................................................. 6A5-8

(6 .2 L )...........................................................................6A6-12
(4 .8 L )...........................................................................6A7-10
Trailer Hitch R eplacem ent............................................ 2A-20
Trailer Hitch Replacement (Utility Vehicle
and S u b u rb a n )........................................................... 2A-13
Transfer Case Capacities Blazer/Jimmy,
S u b u rb a n ...................................................................... OB-2
Transfer Case Capacities Pickup M o d e ls ............. OB-4
Transfer Case Diagnosis (205)......................................7D1-3
Transfer Case Maintenance and
Adjustm ent (205)......................................................... 7D1-2
Transfer Case Replacement (205)...............................7D1-3
Transmission Capacities...................................................OB-1
Transmission Diagnosis, A utom atic............................... 7A-6
Transmission Diagnosis, M anual................................... 7B-2
Transmission Diagnosis, THM 400............................... 7A-16
Transmission Diagnosis, THM 700 R -4 ...................... 7A-35
Transmission Fluid Checking and Adding,
A u to m a tic .................................................................... 7A-63
Transmission Fluid and Filter Changing,
A u to m a tic .................................................................... 7A-66
Transmission Inspection, M anual................................... 7B-1
Transmission Oil Circuits, THM 400 ...........................7A-25
Transmission Oil Cooler and Lines,
A u to m a tic .................................................................... 7A-63
Transmission Oil Drain and Fill, M a n u a l......................7B-3
Transmission Oil and Wiring Circuits,
THM 700 R - 4 ..............................................................7A-43
Transmission Preliminary Checking, THM 4 0 0 .........7A-14
Transmission Preliminary Checking, THM 700 R-4 .7A-31
Transmission Replacement, A u to m a tic ...................... 7A-74
Transmission Replacement, M a n u a l.......................... 7B-10
Transmission Specifications, A utom atic......................7A-74
Transmission Specifications, M a n u a l.......................... 7B-11
TRC D iagnosis..............................................................6E8-43
Turn Signal Switch R eplacem entP(32) M odels..............................................................3B4-33
Turn Signal Switch Replacement
(R, V, G M o d e ls )....................................................... 3B4-16
TV C able........................................................................... 7A-65
TV Cable A djustm ent..................................................... 7A-65
Tune-Up Inform ation......................................................... 6A-2
u
Underbody A lig n m e n t..................................................... 2A-6
Underbody, G M o d e l....................................................... 2A-6
Universal J o in t .................................................................. 4A-1
Unloader Adjustment (M4ME and
M4MEF M od els)....................................................... 6C1-45
V
Vacuum B oosters........................................................... 5A1-3
Vacuum Booster R e p la ce m e n t................................... 5A2-3
Vacuum Modulator (THM 400)......................................7A-67
Vacuum P u m p s ................................................................6H-1
Vacuum Pump Diagnosis.................................................6H-1
Vacuum Pump Replacem ent..........................................6H-4
Vacuum Regulator Valve Adjustm ent
(LL4 Engine with Automatic Transm ission)...........6C2-4
Vacuum Regulator V a lv e .............................................. 6E9-9
PAGE
SECTION
Valve Adjustm ent

(4.3 L). . . .......................................................................6A3-6
(Small Block)................................................................ 6A4-6
(7.4 L)............................................................................. 6A5-4
(4 .8 L )............................................................................. 6A7-5
Valve Stem Seal and Valve Spring Replacement
(4.3 L)............................................................................. 6A3-6
(Small B lo ck)................................................................6A4-7
(7.4 L ) ............................................................................. 6A5-4
(6.2 L)............................................................................. 6 A 6 -8
(4 .8 L )............................................................................. 6A7-5
Valve Timing, Checking (4 .8 L )................................... 6A7-14
Vehicle Em issions C lassification................................... OB-8
Voltmeter R e p la c e m e n t.................................................8C-14
w
WATER IN FUEL Light D ia g n o s is .............................6C-3
Water Pump R eplacem ent.......................................... 6B1-15
W elding............................................................................... 2A-6
Weight Distribution Hitch R e p la ce m e n t....................2A-20
Weight Distribution Hitch Replacement
(Suburban O n ly )......................................................... 2A-14
Weight Distribution Hitch Replacement
(Utility Vehicle O n ly )...................................................2A-15
Wheel and Tire B alancing.............................................. 3E-8
Wheel and Tire Installing.................................................3E-7
Wheel and Tire R u n o u t...................................................3E-4
Wheel Bearing Adjustment, I-B e a m .......................... 3C-32
Wheel Bearing Adjustment, I.F.S..................................3C-13
W heel Bearing Adjustment, 4 W.D.............................. 3C-37
Wheel Bearing/Cup Replacement Full Floating Axle
Wheel Bearings, D iag no sis............................................ 3C-3
Wheel Bolt Replacement Full Floating Axle
Wheel Cylinder R ebuilding................................... . .5A2-11
Wheel Cylinder R eplacem ent..................................... 5A2-11
W heelhouse Panel Replacement (R/V M o d e l)........... 2B-7
Wheel Hub feolt, I-B e a m .............................................. 3C-33
Wheel Hub Bolt, I.F.S......................................................3C-15
Wheel Hub Bolt, 4 W.D.................................................. 3C-41
Wheel Hub/Rotor Assembly, I-Beam .......................... 3C-31
Wheel Hub/Rotor Assembly, I.F.S.................................. 3C-8
Wheel Hub/Rotor Assembly, 4 W.D............................. 3C-36
Wheel Stud Replacement (8 V2 and
9 1/ 2-inch Ring G e a r ) ................................................ 4B1-11
Window Replacement (G M o d e l).............................10A3-10
Window Replacement (RV M odel).............................10A3-3
Windshield Replacement (G M o d e l)........................ 10A3-6
W indshield Replacement (RV M o d e l)...................... 10A3-1
Windshield W a s h e r....................................................... 8A-36
W indshield Washer D iagnosis..................................... 8A-35
W indshield W ip e r........................................................... 8A-26
W indshield W iper D ia g n o sis........................................8A-26
W iper D e la y .................................................................... 8A-38
Wiper Delay D ia g n o s is ................................................ 8A-38
W iper Motor R e p a ir....................................................... 8A-36
SECTION
1 M<eih
Automotive
Service
Educational
Program
E ft
LiS-S'
TECHNICIAN
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
N a tio n a l In s titu te fo r
AUTOMOTIVE
SERVICE
EXCELLENCE
F-02878

ST 330-87-1987 Chevrolet Light Duty Truck Service Manual

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ST 330-87-1987 Chevrolet Light Duty Truck Service Manual

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SEC

HEATING AND AIR CONDITIONING

Front End Alignment

PROPELLER SHAFT AND AXLES

TRANSMISSION AND CLUTCH

W hen reference is m ade in th is m anual

All inform ation, illustrations, and sp eci

Frame and Bumpers

STEERING, SUSPENSION, WHEELS AND TIRES

FRAME AND CAB

So keep that great GM feeling with genuine GM parts

Thats why Mr. Goodwrench wants to have a good

L *-/ - vp 'sEtyg. Ho Ipl

CHEVROLET MOTOR DIVISION

G eneral In fo r m a t io n ........... ................................................................................................................ ....................................0A - 1

S e rvice Parts Id e n tific a tio n L a b e l ........................................................................................................................ ............0 A - 1

THE O P TIO N A L EQ UIPM EN T LISTED 3E LO W H AS BEEN

NOTICE: TH IS IN F O R M A T IO N IS SUPPLIED AS AN AID IN '.DENTIFYING PARTS FOR SERVICE.

IM PO RTAN T: RETAIN TH IS PLATE A S A

F igure 1 S e rvice Parts Id e n tific a tio n Label

OA-2 GENERAL INFORMATION

Figure 2VIN Location

Refer to figures 5 and 6 to determine the vehicle

Gross Vehicle W eight (GVW) is the w eight of the

C h evro let Bus *

Code Body Type

Production Sequence Number

P ickup/P ane l D e livery

Line and Chassis Type

Engine Type and Make

Figure 3Vehicle Identification Number (VIN)

GENERAL INFORMATION OA-3

' MFD. BY GENERAL MOTORS CORPORATION

When lifting the V vehicle with a hoist, the front hoist

When lifting the front of the V vehicle with a floor jack,

Figure 4Certification Label

VEHICLE LIFTING PROCEDURES

When lifting the G vehicle with a hoist, the rear hoist

Figure 5RV Models

OA-4 GENERAL INFORMATION

MAGNAVAN (HI-CUBE VAN)

VALUE VAN (STEP VAN)

MOTOR HOME CHASSIS

FORWARD CONTROL CHASSIS

Figure 6G Van and P Models

GENERAL INFORMATION OA-5

Figure 7Engine I.D. Number Location

OA-6 GENERAL INFORMATION

L ow er c o n tro l arm ; in b o a rd o f th e lo w e r ball jo in t.

Figure 8Chassis Lift Points R Model

Figure 9Chassis Lift Points V Model

GENERAL INFORMATION OA-7

Low er c o n tro l arm ; in b o a rd o f th e lo w e r b all jo in t

Figure 10Chassis Lift Points G Model

Figure 11Chassis Lift Points P Model

OA-8 GENERAL INFORMATION

JUMP STARTING INSTRUCTIONS

M ake C on ne ction s in N um erical O rder

GENERAL INFORMATION OA-9

Figure 13Graphic Symbols

0A-10 GENERAL INFORMATION

G rade 2 (GM 200-M)

Figure 14Bolt and Nut Identification

Figure 15Thread Notation